1997 2003.dt444.engine.service.manual

© 2003 International Truck and Engine Corporation Printed in the United States of America

SERVICE MANUAL

INTERNATIONAL® T 444E

DIESEL ENGINESERVICE MANUAL

MODEL YEARS LATE 1997-2003

Due to a continuous program of research and development, some procedures, specifications and parts may be altered in a constant effort to update and improve our products.

Periodic revisions may be made to this publication and mailed automatically to dealers. It is recommended that customers contact their dealer for information on the latest revision.

SERVICE MANUALINTERNATIO

NAL® T 444E

DIESEL ENGINE

MO

DE

L YE

AR

S 1997-2003

EG

ES

205, OC

TOB

ER

2003


SERVICE MANUAL


DIESEL ENGINESERVICE MANUAL




NAL® T 444E

DIESEL ENGINE

MO

DE

L YE

AR

S 1997-2003


SERVICE MANUAL


DIESEL ENGINE




NAL® T 444E

DIESEL ENGINE

MO

DE

L YE

AR

S 1997-2003

FORM EGES-205SERIAL NUMBER 634234 AND UP

ENGINE SERVICE MANUAL I

Table of Contents

Foreword.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Service Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Mounting Engine On Stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Manifolds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

Cylinder Head And Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

Oil Pan, Vibration Damper, Oil Pump Water Pump, And Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123

Valve Train: Push Rods, Hydraulic Valve Lifters And Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143

Crankcase, Crankshaft, Connecting Rods, And Pistons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157

Thermostat And Coolant Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .209

Oil Cooler And Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .217

Engine Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .223

High-pressure Oil Pump.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .243

Fuel System.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .255

Appendix A – Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .267

Appendix B — Torques.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .277

Appendix C — Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .287

EGES-205Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.

Follow all warnings, cautions, and notes.©2003 International Truck and Engine Corporation

II ENGINE SERVICE MANUAL



ENGINE SERVICE MANUAL 1

ForewordThis publication provides general and specific serviceprocedures and repair methods essential for reliableengine operation and your safety. Since manyvariations in procedures, tools, and service parts areinvolved, advice for all possible safety conditions andhazards cannot be stated.

Departure from instructions in this publication ordisregard of warnings and cautions can lead to injuryor death, or both and damage to the engine or vehicle.

Read safety instructions below before doing serviceor test procedures in this publication for the engineor vehicle. See related engine manuals for moreinformation.

Periodic revisions may be made to publications.When ordering publications, the latest revision will besupplied.

The following literature supporting International®Diesel Engines is available from:

International Truck and Engine CorporationPrinting & Distribution Center61 Clark Road NorthBattle Creek, Mich. 49015(269) 968–4856

1171737R7 – T 444E Diesel Engine Operation andMaintenance ManualEGES-120–1 – T 444E Diesel Engine Service Manual1994–1997, S/N 634233 And DOWNEGES-205 – T 444E Diesel Engine Service Manual1997–2003, S/N 634234 And UPEGES-190 – T 444E Diesel Engine Diagnostic ManualEGED-140 – Supplemental Coolant Level Ref. Chart(for conventional GREEN coolant)EGED-195 – Hard Start / No Start PerformanceDiagnostic FormEGED-200 – Electronic Control System DiagnosticForm



2 ENGINE SERVICE MANUAL

Service DiagnosisService diagnosis is a systematic procedure ofinvestigation to be followed in order to locateand correct an engine problem. The engine isfirst considered as a complete unit in its specificapplication and then the problem is localized tocomponents or systems; intake, exhaust, cooling,lubrication or injection. Testing procedures will thenhelp analyze the source of the problem.

PREREQUISITES FOR EFFECTIVE DIAGNOSIS:

• Knowledge of the principles of operation for boththe engine and application systems

• Knowledge to perform and understand allprocedures in the diagnostic and servicepublications

• Availability of and the ability to use gauges anddiagnostic test equipment

• Availability of the most current information for theengine application

Although the cause of an engine failure may beapparent, very often the real cause is not found until arepeat failure occurs. This can be prevented if specificdiagnostic action is taken before, during and afterengine disassembly and during engine assembly.

It is also very important that specific diagnostic testsfollow engine assembly before and after the engine isplaced back into service.

Identification of the symptoms which lead to enginefailure is the result of proper service diagnosis.Effective service diagnosis requires use of thefollowing references:

• Engine Service Manual

• Hard Start and No Start Diagnostics

• Performance Diagnostics

• Electronic Control Systems Diagnostics

• Service Bulletins

NOTE: Metric values precede English values for testprocedures and reference.

Examples: 96 kPa (14 psi), 20 C (68 F)

This publication is arranged in sections. Any photosand artwork are also numbered consecutively fromthe beginning of the publication. An index arrangedaccording to sections is located at the beginning ofthe publication.



ENGINE SERVICE MANUAL 3

Safety InformationThis manual provides general and specific serviceprocedures and repair methods essential for reliableengine operation and your safety. Since manyvariations in procedures, tools, and service parts areinvolved, advice for all possible safety conditions andhazards can not be stated.

Departure from instructions in this manual ordisregard of warnings and cautions can lead toinjury or death, or both and damage to the engine orvehicle.

Read safety instructions below before doing serviceand test procedures in this manual for the engine orvehicle. See related application manuals for moreinformation.

SAFETY TERMINOLOGY

Three terms are used in this manual to stress yoursafety and safe operation of the engine: Warning,Caution, and Note.

Warning: Signals conditions, hazards, and unsafepractices that can cause injury or death.

Caution: Signals conditions and practices that cancause damage to the engine or vehicle.

Note: Signals a key point or procedure that must befollowed for correct, efficient engine operation.

SAFETY INSTRUCTIONS

Vehicle

• Make sure the vehicle is in neutral, the parkingbrake is set, and the wheels are blocked beforedoing any work or diagnostic procedures on theengine or vehicle.

Work area

• Keep work area clean, dry, and organized.

• Keep tools and parts off the floor.

• Make sure the work area is ventilated and well lit.

• Make sure a First Aid Kit is available.

Safety equipment

• Use correct lifting devices.

• Use safety blocks and stands.

Protective measures

• Wear protective glasses and safety shoes (do notwork in bare feet, sandals, or sneakers.)

• Wear correct work clothing.

• Do not wear rings, watches, or other jewelry.

• Restrain long hair.



4 ENGINE SERVICE MANUAL

Fire prevention

• Keep a charged fire extinguisher close by.

NOTE: Three kinds of fire extinguishers are required:

1. Type A — Wood, paper, Textiles, and rubbish

2. Type B — Flammable liquids

3. Type C — Electrical equipment

Batteries

Batteries produce highly flammable gas during andafter charging.

• Avoid leaning over batteries.

• Protect your eyes.

• Do not expose batteries to open flames or sparks.

• Do not smoke.

• Always disconnect the ground cable beforeworking on the electrical system.

Compressed air

• Limit shop air pressure for blow gun to 207 kPa(30 psi).

• Use approve equipment.

• Do not direct air at body or clothing.

• Wear safety glasses or goggles.

• Use shielding to protect others in the work area.

Tools

• Make sure all tools are in good condition.

• Make sure all standard electrical tools aregrounded.

• Check for frayed power cords before using powertools.

Fluids under pressure

• Use extreme caution when working on systemsunder pressure.

• Follow approved procedures only.

Fuel

• Do not over fill the fuel tank. Over fill creates a firehazard.

• Do not smoke in the work area.

• Keep the funnel or nozzle of the hose in solidcontact with the metal of the fuel tank inlet. Solidcontact will prevent electrical sparks.

• Do not refuel the tank when the engine is running.

Removal of tools, parts, and equipment

• Reinstall all safety guards, shields, and coversafter servicing the engine.

• Make sure all tools, parts, and service equipmentare removed from the engine and vehicle after allwork is done.



INTRODUCTION 5

Table of Contents

Engine Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Serial Number Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Emission Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Engine Component Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Engine Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13General Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13Chassis Mounted Charge Air Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13Cooling System.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15Thermostat Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Lubrication System.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17Oil Flow.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Air Induction and Exhaust System.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Fuel System.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Injection Control Pressure System.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24Injection Pressure Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26IPR Valve Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Fuel Injector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28Component Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Glow Plug Controller System.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30



6 INTRODUCTION



INTRODUCTION 7

Engine IdentificationSerial Number Location

The engine serial number is permanently stamped onthe crankcase pad on the lower rear left side of theengine.

Figure 1 Engine Serial Number Location

Explanation of the Engine Serial Number

7.4 – Engine Identification CodeH – Type of Code: H=Diesel, turbocharged, air cooledand electronically controlledM2 – End Use Code: M2=Truck, A2=Stripped andserviceU – Country of Origin: U=U.S.A. orN – Country of Origin: N=Brazil (IESA)XXXXXX – Engine serial number sequence

Other nameplates on the turbocharger and auxiliarydevices like the starter provide manufacturerspecifications and inform the operator or maintenancepersonnel of the type of equipment that is on theengine and its range of operating conditions.

Emission Label

Figure 2 Emission Label Location

The emission label is located on the left valve cover.

The emission label identifies an engine’s model code,the year it was manufactured, the year the engine wascertified to meet government emission standards, andother relevant information. This label exists in multiplelanguages.



8 INTRODUCTION

Engine Component Location

Figure 3 Component Location, (Front View)

1. Lube Oil Fill Tube2. Turbocharger Air Outlet Tube (to

CAC)3. High-pressure Pump Oil

Reservoir4. Water Outlet and Thermostat

Housing

5. Water Pump6. Coolant Filter7. Crankshaft Vibration Damper

Pulley8. Engine Front Mount Support9. Camshaft Position Sensor10. Water Pump Inlet

11. Coolant Temperature Sensor12. ECM International Diamond

Logic™13. Water Pump Pulley



INTRODUCTION 9

Figure 4 Component Location, (Left Side View)

1. Fuel Filter2. Turbocharger Air Outlet Tube (to

CAC)3. Turbocharger4. Crankcase Breather

5. Road Draft Tube6. Rear Lifting Eye7. Exhaust Manifold8. Rear Engine Mounting Bracket9. Lube Oil Filter

10. Oil Pan11. Oil Cooler12. Coolant Filter13. Valve Cover14. Front Lifting Eye



10 INTRODUCTION

Figure 5 Component Location, (Rear View)

1. Turbocharger2. Turbocharger Exhaust Outlet

With Optional Exhaust BackPressure Control Valve

3. ECM International DiamondLogic™

4. Right Side Exhaust Tube WithBellows

5. Crankshaft6. Rear Engine Mounting Bracket,

Right Side7. Fuel Filter Water Drain Tube

8. Flywheel Housing9. Rear Engine Mounting Bracket,

Left Side10. Left Side Exhaust Tube With

Bellows11. Rear Lifting Eye



INTRODUCTION 11

Figure 6 Component Location (Right Side View)

1. Air Outlet2. Fuel Filter Pre-Strainer3. Fuel Filter4. Fuel Pressure Regulator5. ECM International Diamond

Logic™6. Valve Cover

7. Oil Level Gauge8. Coolant Heater Supply9. Coolant Heater Return10. Oil Pan11. Rear Engine Mounting Bracket12. Exhaust Manifold13. Turbocharger



12 INTRODUCTION

Figure 7 Component Location, (Top View)

1. Turbocharger Air Inlet Elbow2. Crankcase Breather3. Turbocharger Air Outlet Tubes

(to and from CAC)4. High-pressure Oil Supply

Manifold, Left Hand Side(Integral part of cylinder head)

5. High-pressure Oil Pump

6. ECM – International DiamondLogic™

7. Glow Plug Controller8. High-pressure Oil Supply

Manifold, Right Hand Side(Integral part of cylinder head)

9. Manifold Absolute PressureSensor (MAP)

10. Turbocharger Assembly



INTRODUCTION 13

Engine DescriptionGeneral Features

The International® T 444E diesel is a four strokeV8 engine. It features overhead valves and iswater-cooled and turbocharged. The engine isfueled by a direct injection fuel system with electronicsensors and Hydraulically actuated Electronicallycontrolled Unit Injectors (HEUI). It has a displacementof 7.3 liters (444 cubic inches).

When viewing the engine from the rear (flywheel end),the right hand bank of cylinders are numbered 1, 3,5, and 7. Cylinder number 1 is at the front. Theleft bank consists of cylinders 2, 4, 6, and 8. In thiscase, cylinder number 2 is at the front. The enginesnumerical firing sequence is 1–2–7–3–4–5–6–8.

The International Diamond Logic™ ElectronicControl Module (ECM) monitors and controls engineperformance to ensure optimal efficiency, andadherence to emissions standards. The ECM is alsoable to monitor and control vehicle features.

The crankcase has been especially designed towithstand the loads of diesel operation and utilizes afour bolt main bearing cap to assure a rigid supportfor the rotating parts. The crankcase also has pistonoil cooling jets and their function is to direct oil to theunderside of the piston to help dissipate heat to thelube oil.

The crankshaft is a five main bearing unit with fore andaft thrust controlled at the rear (Number 5) bearing.

Connecting rods are attached to the crankshaft. Twoconnecting rods share each crankpin journal. Therewere two types of connecting rods used on this enginefor model years 1997 and above. The connecting rodsare easily identified by the way the connecting rod capis secured to the connecting rod.

• Forged steel connecting rods were used onengines with serial numbers ranging from 634234to 1498318. The connecting rod caps are securedto the connecting rod with bolts and nuts.

• Powered metal forged steel connecting rods wereused on engines with serial numbers ranging from1498318 and up. The connecting rod caps forthese later style connecting rods are secured withbolts that thread into the connecting rod (no nutsused).

The piston pin is a free floating type. It permits thepin to move or float freely in the piston and connectingrod. The piston pin is held in place with two piston pinretaining rings.

The camshaft is supported by five insert-type bearingspressed into the crankcase, and is gear driven fromthe crankshaft. The end thrust of the camshaft iscontrolled by a thrust flange located between the frontcamshaft journal and the cam gear.

The aluminum-alloy pistons are fitted with twocompression rings and one oil ring. The topcompression is a keystone configuration.

The hydraulic valve lifters minimize engine noise andmaintain zero valve lash or tappet clearance. Thiseliminates the need for periodic adjustment of thevalve lash. The hydraulic valve lifters have rollerfollowers which provide excellent camshaft and lifterdurability.

The one piece cylinder heads used on the engine areequipped with a positive valve rotating mechanism onboth the intake and exhaust valves. This device iscalled a rotator and it is located at the top of each valvespring.

An electrically controlled glow plug system providesoutstanding cold weather starting capability. Anoptional block heater is available to warm coolant atextremely cold ambient temperatures below -29 C(-20 F).

Some of the features incorporated in this series ofengines include a gerotor lube oil pump (driven directlyby the crankshaft at engine speed), cast water and oilpassages in the crankcase and front cover, spin-ontype lube oil filter, fuel filter/strainer assembly, andspin-on type coolant filter.

Chassis Mounted Charge Air Cooler

The T 444E diesel engine utilizes a charge air cooling(CAC) system. The cooler is chassis mountedadjacent to the radiator. Air from the turbochargeris pushed through a network of heat exchangingtubes before entering the intake manifold. Outside airflowing over the fins and tubes serves to cool the aircharge. The resulting cooled intake air is denser thanthe compressed (warmed) air, allowing for improvedfuel/air ratio in the cylinders during the combustionprocess. The results are improved emission controland increased power output.



14 INTRODUCTION

Cooling System

Figure 8 Engine Coolant Flow Diagram

1. Water Pump2. Thermostat3. Outlet Tube4. Front Cover5. Crankcase

6. Cylinder Head7. Lubricating Oil Filter8. Oil Cooler9. Coolant Filter10. Water Pump Inlet



INTRODUCTION 15

Description

The function of the cooling system is to keep theengine within a designated temperature range. Majorcomponents of most cooling systems include aradiator and fan combination with a water pump,thermostat, oil cooler, and coolant filter. The waterpump is a belt-driven centrifugal type, which is setinto the front cover.

The front cover incorporates two separate passages.One passage channels coolant from the water pumpto the crankcase. The other passage is a bypassthat routes coolant back to the water pump when thethermostat is closed. The thermostat starts to open at89 C (192 F) and is fully open at 104 C (219 F).

Coolant flows from the bottom of the radiator into theinlet tube of the water pump, and into the front cover.Coolant is pushed by the impeller in the water pump,through an internal passage in the front cover, andout into the crankcase. An internal passageway in thecrankcase directs coolant from the front to the rear,evenly distributing coolant around the cylinders andinto the cylinder heads.

Coolant leaves the cylinder head in the following twoways:

• The coolant is directed, via an internal passage inthe crankcase, to the oil cooler header. Coolantflows through passages in the oil cooler and existsat the water pump, to be mixed with incomingcoolant from the radiator.

• Coolant exists from the cylinder head, flowsthrough an internal passage in the crankcase,and into the front cover. It is then directed to thewater pump passage containing the thermostat.

Thermostat Operation

The thermostat incorporates two outlets that workindependently to channel coolant to two differentparts of the engine. One outlet carries coolant to theradiator, the other outlet directs coolant back to thewater pump.

When the engine coolant temperature is below thespecified thermostat opening temperature, the outletto the radiator is thermally blocked. This blockageforces coolant to flow through the bypass passageback into the water pump. As the engine approachesits normal operating temperature, the thermostatopens, closing off the bypass passage and allowingcoolant to flow towards the radiator.



16 INTRODUCTION

Lubrication System

Figure 9 Lubrication System Diagram

1. Camshaft Gear2. Camshaft Thrust Plate3. Camshaft4. High-pressure Pump Oil

Reservoir5. Piston Cooling Jets (8)6. Hydraulic Valve Lifter Oil Gallery7. Turbocharger Pedestal

8. Turbocharger Assembly (Typical)9. Hydraulic Valve Lifter10. Push Rod11. Valve Lever Assembly12. Intake/Exhaust Valve13. Main Oil Gallery14. Main Crankshaft Bearings15. Oil Filter Bypass Valve

16. Oil Filter17. Oil Pressure Regulating Valve18. Oil Cooler19. Oil Cooler Header20. Oil Pick-Up Tube21. Oil Pump22. Connecting Rod Bearings23. Check Valve



INTRODUCTION 17

Description

The lubrication system is pressure regulated, cooled,and full flow filtered. In addition to providing enginelubrication, pressurized lube oil is used to control fueldelivery to the HEUI fuel injectors.

Oil Flow

Lube oil is drawn from the oil sump, through the pickup screen and tube, and into the oil pump. The oilpump is of the gerotor type with the inner rotor portiondriven directly by the crankshaft. The pump housing,containing the inner and outer gerotor gears, isbolted onto the front cover. The pump inlet and outletpassages are ports in the front cover. Upon leavingthe oil pump, unfiltered lube oil enters the front oilcooler header through a passage in the front cover.

At initial engine start up, a small portion of the oil ispassed directly from the pump to the high pressurepump oil reservoir on top of the front cover. Oil flowsfrom the oil cooler header around the oil cooler tubesinto the oil filter assembly. The oil enters the oil filterthrough the outside of the filter element and flowsthrough the filtering medium to the center. The filteredoil now passes through the oil gallery in the crankcase.The oil pressure regulator controls lube oil pressurevia a spring loaded plunger which relays oil back tothe sump once operating pressure is reached. Therear oil cooler header supports the oil filter, which alsocontains a bypass valve that allows oil to pass directlyto the main oil gallery if the filter becomes excessivelyrestricted.

The five crankshaft main bearings are oil fed throughdrilled passages in the crankcase directly from themain oil gallery. Connecting rod bearings receivepressurized oil from the main bearings through

drilled passages within the crankshaft. The camshaftjournals receive pressurized oil through passagesdrilled vertically through the main bearing webs.

Two tappet galleries, which are fed from the main oilgallery through the holes of main bearing bolt number1, intersect each tappet bore to provide pressurizedlube oil to the valve lifters and piston cooling jets. Thevalve lever assemblies and push rods are lubricated byoil passing from the lifter ball socket upward throughthe hollow push rods to valve lever arms. Oil drainsback to the sump through holes located at each endof the cylinder head.

The oil reservoir, which is used to maintain a readysupply of oil to the high pressure pump, is filled viatwo passages. At initial start up, oil is directed fromthe oil pump discharge port through a passage inthe front cover and crankcase, which also contains acold startup bypass check valve. To ensure sufficientoil pressure to operate the injectors for quick starts,this reservoir oil supply quickly replenishes oil tothe high pressure pump during cold cranking. Theprimary reservoir oil supply is continuously fed fromthe left bank tappet gallery through the front cover,and discharges oil near the top of the reservoir.

Pressurized lube oil reaches the turbochargerbearings from the main oil gallery (left bank) througha passage in the turbocharger pedestal (mountingpad). Oil drains from the turbocharger throughanother adjacent passage in the pedestal directlyback to the sump. This oil supply and drain eliminatethe need for external lube lines to the turbocharger.

Hydraulic oil pressure that is used to actuate theexhaust back pressure (EBP) warm-up control isreceived from the turbocharger lube supply port. Thisport is located in the turbocharger support pedestal.



18 INTRODUCTION

Air Induction and Exhaust System

Figure 10 Air Induction/Exhaust System Diagram

1. Charge Air Cooling Tube2. Turbocharger Air Inlet Assembly3. Turbocharger Compressor

Assembly4. Turbocharger Center Housing

5. Turbocharger Turbine Housing6. Muffler7. Right Hand Exhaust Manifold8. Left Hand Exhaust Manifold



INTRODUCTION 19

Description

The intake and exhaust systems consist of thosecomponents that contain the flow of filtered airinto the engine cylinders and exhaust gases to theatmosphere.

The turbocharger is used to increase enginepower output by increasing the air supply to theengine, resulting in more uniform performanceat various operating altitudes. The turbochargerincorporates an exhaust driven air compressorthat allows filtered air to enter the center of theair compressor where it undergoes an increase inpressure from “atmospheric” to “boost” as it flows intothe combustion chambers. After combustion, hot andexpanding exhaust gases move out of the cylindersand into the turbine housing driving the turbine wheel.The turbine wheel drives the compressor wheelthrough a solid common shaft allowing the engine torespond directly to changing engine loads. Duringheavy loads, an increased flow of exhaust gas spinsthe turbine wheel faster causing the compressorimpeller to spin in direct relation, supplying greatervolumes of air (boost) into the intake manifold andcylinders. Conversely, with lighter engine loads, theflow of exhaust gas decreases as does the volumeof air being compressed into the intake manifold andcylinders.

Some engines are equipped with an optional exhaustback pressure device to allow for a faster warm-up ofthe engine and passenger compartment when heatis needed. This device increases heat production.It uses a butterfly valve located in the exhaust sideof the turbocharger housing. When the exhaustis restricted by the butterfly valve, exhaust backpressure increases, forcing the engine to work harderto expel the exhausted gases. When the valve isopen, exhaust gases flow out freely.

The hot boost air from the compressor is cooledby a charge air cooler before entering the intakemanifold. Air then flows into the combustion chamberwhere the required quantity of fuel is injected, ignitingthe combustion phase. Exhaust gases leave thecylinders through exhaust ports and the exhaustmanifold. From the exhaust manifold, the expansionof exhaust gases on the exhaust turbine drive theturbocharger and are released through an exhaustpipe into the atmosphere.

The exhaust system includes exhaust valves, anexhaust manifold, exhaust piping and a muffler. Theturbocharger turbine side is also an integral partof the exhaust system. The compressor side is acomponent of the induction or intake system.



20 INTRODUCTION

Fuel System

Figure 11 Major Fuel System Component Locations

1. Fuel Supply (Transfer) Pump2. Fuel Pressure Regulating Valve

3. Fuel Return Port4. Fuel Filter Canister

5. Fuel Inlet6. Fuel Strainer

Description

The function of the fuel system is to deliver fuel fromthe fuel tank(s) through a filter to the fuel injectorsat a regulated pressure. The fuel injectors use highpressure lube oil to pressurize the fuel and inject it intothe combustion chambers.

The fuel system consists of the following components:

• Fuel tank(s)

• Fuel supply lines and return line

• Fuel filter

• Fuel passages that feed the fuel injectors

• Fuel pressure regulator

• Fuel supply (transfer) pump



INTRODUCTION 21

Figure 12 Fuel Supply (Transfer) Pump Diagram

1. Low Pressure Fuel Outlet2. Outlet Check Valve3. Spring4. High-pressure Outlet5. Outlet Check Valve6. Fuel Seal7. Oil Seal8. Camshaft Lobe9. Tappet10. O-ring11. Inlet Check Valve12. Inlet13. Piston14. Spring15. Diaphragm16. Inlet Check Valve17. Fuel Inlet

The fuel supply (transfer) pump is a camshaft driven,two stage diaphragm/piston pump. This pump ismounted in the engine "V."

Operation

The diaphragm stage of the tandem lift pump drawsfuel from the tank through a fuel strainer located onthe fuel filter housing. Fuel is then delivered to thefuel filter under low pressure of less than 67 kPa (10psi). Air that is trapped in the filter is vented back tothe tank through an opening (or hole) in the regulatorblock mounted on the filter housing. This openingis protected from plugging by a wire mesh screenlocated inside the filter housing.

Fuel in the filter housing passes through the filterelement to a standpipe in the center of the filterassembly. Clean fuel then passes to the inlet side ofthe piston stage located on the tandem pump.

NOTE: The fuel filter element is attached to thethreaded filter cover. When servicing, the elementcan be separated from the cover and replaced witha new element. Fuel flow will be interrupted withoutthe fuel filter element in place. The standpipe in thecenter of the housing contains a shut off valve that isopen only when the filter element is in place.

The piston stage of the tandem pump raises fuelpressure to ensure proper filling of the fuel injectors.Fuel from this stage is delivered to one end of eachcylinder head. These lines supply fuel to a gallerydrilled in each cylinder head. Fuel enters at the rearof the right cylinder head and the front of the leftcylinder head. No fuel returns to the fuel tank fromthe cylinder heads.

On some engines, the base of the filter housingcontains an electric heating element that is usedto warm fuel. Heating helps prevent the fuel fromwaxing during cold weather. Also located in the baseof the housing is a sensor to detect the presence ofwater in the fuel (optional). When sufficient water hascollected in the bottom of the filter, the sensor willilluminate a ’water in the fuel’ lamp located on theinstrument panel.



22 INTRODUCTION

Figure 13 Split Shot Injector Fuel System Schematic

These engines are equipped with the split shot fuelinjectors. A fuel inlet check valve is used in eachcylinder head. The inlet check valve dampens thepulses in the fuel rail in the cylinder head. There areno return lines from the galleries on this system.

The pressure regulator contains a spring loaded valveto control pressure in the fuel galleries. Return fuelflows through the regulator and is routed back to thefuel tank(s). No fuel is returned to the fuel tank(s) fromthe cylinder heads with split shot fuel system flow.



INTRODUCTION 23

Injection Control Pressure System

Figure 14 Injector Oil System Diagram (Left Side)

1. Lubricating Oil Pump2. Reservoir (Located On Top of

Front Cover)3. High – pressure Pump4. High – pressure Lines

5. Injection Control Pressure (ICP)Sensor

6. Cylinder Head High PressureOil Rail (2)

7. Fuel Injectors (8)

8. Crankcase Main Oil Gallery9. Oil Filter10. Oil Cooler11. Injection Control Pressure

Regulator



24 INTRODUCTION

Figure 15 ECM And IPR Configuration

Operation

The injection control pressure system utilizes ahydraulically actuated injector to pressurize fuelinside the injector. The hydraulic fluid used to actuatethe injector is engine oil.

Oil is drawn from the oil pan through the pick uptube by the engine oil pump. The engine oil pumpis a gerotor type pump driven by the crankshaft. Atstart-up, oil is fed through passages in the front coverto an oil reservoir mounted on top of the front cover.Once the engine is running, oil is supplied throughthe left lifter oil gallery.

The reservoir makes available a constant supply ofoil to a high pressure hydraulic pump mounted in theengine "V." The high-pressure pump is a gear drivenseven plunger swash plate pump. High pressure oilis delivered by the high pressure pump, through highpressure oil lines, to oil galleries machined into thecylinder heads. Drilled intersecting passages supplyhigh-pressure oil to the fuel injectors.



INTRODUCTION 25

This high-pressure oil is utilized by the Hydraulicallyactuated Electronically controlled Unit Injectors(HEUI) when the solenoid is energized to pressurizeand atomize the fuel into the combustion chamber.After injection is complete, the solenoid isde-energized and the oil inside the injector is ventedthrough the top portion of the injector, splashed onthe valve train and allowed to drain back into the oilpan.

The injection control pressure system is a closed loopoperating system that consists of the electronic control

module (ECM), injection control pressure (ICP) sensorand injection pressure regulator (IPR) valve.

The ECM is programmed with an injection pressurecontrol strategy which determines the correct injectioncontrol pressure at all engine operating conditions.The ECM receives a 0 – 5 volt (DC) analog feedbacksignal from the ICP sensor located in the highpressure oil supply gallery on the left cylinder headthat indicates injection control pressure. The ECMprocesses this signal and controls injection controlpressure by controlling the ground to the IPR valve.



26 INTRODUCTION

Injection Pressure Control

Figure 16 Closed Loop Operation Diagram

The ECM controls the injection control pressure byoperating the IPR valve. The result of this controlis continuously monitored by the ECM using the ICPsensor. The pressure signal obtained from the ICPallows the ECM to know the actual injection controlpressure at all times of engine operation, even duringcranking mode. This operation is known as "ClosedLoop."

Diagnostic codes can be set by the ECM if the ICPelectrical signal is out of range or if the ICP signalreceived corresponds to an out of range value forthe injection control pressure at a given operatingcondition.

Should any of these occur, the ECM will ignore theICP signal and control the IPR valve operation frompreviously programmed default values. This conditionis known as an "Open Loop."

IPR Valve Operation

The IPR valve is a pulse width (duty cycle %)modulated valve operating at 400 Hz. The pulsewidth is modulated between 8 and 60% to controlICP pressure. The regulator is mounted in the high

pressure pump. The regulator maintains the desiredinjection control pressure by dumping excess oilthrough an internal spool valve. The excess oil thentravels, through an internal stand pipe, into the frontcover and back to the oil pan.

As the demand for injection control pressureincreases, the ECM increases the pulse width(duty cycle %) over the IPR solenoid. This actionforces the poppet against the drain hole, therebyincreasing the pressure behind the spool valve.

As oil pressure increases behind the spool valve, itmoves forward and blocks the drain ports on the sidesof the IPR valve.

When the demand for injection control pressuredecreases, the ECM decreases the pulse width (dutycycle %) over the solenoid allowing oil to drain out ofthe drain hole. This is accomplished by relieving thepressure behind the spool valve. This reduction inpressure allows the spool valve to partially open therelief port, decreasing the injection control pressure.

The described operation allows the IPR tocontinuously adjust the injection control pressurecommanded by the ECM.



INTRODUCTION 27

Figure 17 IPR Higher Injection Pressure Diagram

Figure 18 IPR Lower Injection Pressure Diagram



28 INTRODUCTION

Fuel Injector

Description

The fuel injector is a unitized fuel injector that ishydraulically actuated and electronically controlled.

Hydraulic actuation is accomplished when the injectorsolenoid is energized, opening a poppet valve andallowing ICP pressure to flow on top of the amplifieraccumulator.

Fuel is supplied to the injector by passages drilledthrough the cylinder head that intersect fill ports in theinjector.

The area under the plunger is filled with fuel frompressure supplied by the transfer pump. As theplunger moves down, the increase in pressure closesthe fuel inlet check ball. Pressure continues to riseuntil the nozzle valve pressure setting is overcome.Fuel is pressurized through the nozzle orifices andatomized into the combustion chamber. Injection isterminated when the solenoid is de-energized andICP pressure is released.

Component Description

Solenoid

The solenoid is a very fast acting electromagnet that,when energized, pulls the poppet valve off its seat.

Poppet Valve

The poppet valve is held on its seat by a spring. In thisclosed position, high pressure inlet oil is blocked andthe intensifier cavity is opened to drain.

When the solenoid is energized, the poppet is quicklylifted off its seat. The passage to the drain is closedand the inlet for high pressure oil is opened.

Intensifier Piston and Plunger

When the poppet valve opens the inlet port, highpressure oil enters the injector and acts on the topof the intensifier piston. Pressure builds on theintensifier, pushing it and the plunger down. Theintensifier is seven times larger in surface area thanthe plunger. This difference allows for an equalmultiplication of force. The downward movement ofthe plunger pressurizes the fuel in the plunger cavity,causing the nozzle to open.

Figure 19 Fuel Injector Component Location

1. Solenoid2. Poppet Valve3. Intensifier Piston4. Check Ball5. Nozzle Assembly6. Nozzle Valve

Operation

These engines are equipped with split shot fuelinjectors. The injection operation is divided into twostages or cycles.

1. Pre-injection

2. Primary injection



INTRODUCTION 29

Figure 20 Stages of Injector Operation

The injection cycle is executed in two stages. Somefuel is pre-injected into the combustion chamberto initiate the combustion. Following combustioninitiation, the primary injection takes place. Thisfeature reduces emission levels during light loadoperations. It also reduces light load engine noise.

The barrel and plunger were redesigned and a spillport was incorporated. When injection is initiated, the

first shot of fuel is pre-injected into the combustionchamber. Pre-injection is complete when the spill portof the plunger coincides with the slot on the barrel.

At this time, some fuel is allowed to return to thefuel supply port until the spill port slot is once againblocked by the plunger and the primary injection stroketakes place.



30 INTRODUCTION

Glow Plug Controller System

Figure 21 Glow Plug Controller System Diagram

The purpose of the glow plug system is to warm upthe engine cylinders to improve cold engine startingand to reduce exhaust emissions during the enginewarm-up period.

The ECM is programmed to turn on the "wait to start”light. The ECM also energizes the glow plugs via theglow plug relay each time the ignition switch is placedin the ON position before starting an engine.

The ECM monitors battery voltage and usesinformation from the Engine Coolant Temperature(ECT) and barometric (BARO) sensors to determinethe amount of "wait to start” light time and glow plugactivation time. The ECM controls the "wait to start”

light ON time and the activation of the glow plugsseparately.

The glow plugs are activated for a longer period of timeif the engine is cold or the barometric pressure is low(high altitude). Battery voltage is monitored to extendglow plug life. If the battery voltage is high, power tothe glow plugs is modulated by turning the glow plugrelay ON or OFF at programmed intervals.

The engine is ready to start when the "wait to start"light is turned off by the ECM. To reduce exhaustemissions during engine warm up, the glow plugs mayremain ON for up to 120 seconds while the engine isrunning.



MOUNTING ENGINE ON STAND 31

Table of Contents

Mounting Engine On Stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Special Torque.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35



32 MOUNTING ENGINE ON STAND




Mounting Engine On Stand

Figure 22 Location of Coolant Drain Plugs

1. Right Coolant Drain Plug2. Oil Level Gauge3. Left Exhaust Manifold4. Left Coolant Drain Plug5. Oil Cooler/Filter Header

1. Drain the coolant from the crankcase by removingtwo coolant drain plugs. The drain plugs arelocated at the rear of the crankcase, behind theexhaust manifolds on each side of the engine.

2. After the coolant has drained, install coolant drainplugs into crankcase and tighten.

3. Dispose of the coolant according to localregulations.

Figure 23 Location of Oil Drain Plug

1. Oil Pan2. Oil Drain Plug

4. Remove the oil drain plug. Allow the oil to draininto a suitable container.

5. After oil has drained, install the oil pan drain plugand tighten to the special torque value.

6. Dispose of the oil according to local regulations.

Figure 24 Removing Oil Level Gauge

1. Oil Level Gauge2. Stud Nut3. Right Exhaust Manifold




7. Loosen the stud nut that secures the slotted oillevel gauge mounting bracket to the right exhaustmanifold. Remove the oil level gauge.

WARNING: To avoid personal injury orpossibly death, attach the hoist hook liftingbracket at the engine lifting eyes beforelifting the engine. Failure to do so can causethe engine to lift on one end and swing out,injuring any personnel standing in the area.

8. Attach the hoist hook lifting bracket at the enginelifting eyes. Use a safety catch on the hoist hookwhen lifting the engine.

WARNING: To avoid personal injuryor possibly death, or engine damage, useonly grade 8 or greater metric bolts whenmounting the engine to the stand. Otherbolts may sheer, causing the engine to fallfrom the engine stand.

NOTE: For specific directions on the safe use ofengine mounting stands and adapter plates, refer tothe manufacturer’s instructions included with theseparts.

NOTE: Use the correct engine stand adapter platewhen mounting the engine to the stand.

Figure 25 Installing Engine Stand Adapter Plateto Engine

1. Engine Mounting Adapter Plate2. Spacer3. Mounting Bolts (3)

9. Position and secure engine stand mountingadapter plate to right side of engine. Use threegrade 8 bolts.

10. Mount engine to stand using the specified adapterplate and grade 8 or greater mounting bolts.




Special Torque

Table 1 Engine Mounting Special Torques

Oil Level Gauge Tube Adapter Nut 36 N·m (26 lbf·ft)

Oil Pan Drain Plug 41 N·m (30 lbf·ft)

SPECIAL SERVICE TOOLS

Table 2 Engine Mounting Special Service Tools

ZTSE4151A Rear Mounted Engine Bracket (Keine Stand) (Not shown)

ZTSE4348 Side Mounted Engine Bracket (OTC Stand)

OEM4137 Engine Turn-Over Stand



TURBOCHARGER 37

Table of Contents

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39Bellows Exhaust System Feature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47Standard Torque Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47High Torque Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Cleaning.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54Related Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Disassembly (Standard Torque Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54Remove EBP Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54Remove Turbocharger Pedestal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55Check Exhaust Inlet Adapter/Exhaust Tube Mating Surface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55Compressor Impeller, Turbine Wheel and Turbocharger Pedestal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56Check Axial End Play. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56Rebuild EBP Piston Rod Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57Check Wastegate Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Assembly (Standard Torque Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59Install Turbocharger Pedestal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59Install EBP Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61Standard Torque Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61High Torque Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Special Torque.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68




38 TURBOCHARGER



TURBOCHARGER 39

Description

The turbocharger is an exhaust driven centrifugal aircompressor. It’s purpose is to increase power outputby supplying compressed air to the engine. Theinternal components are oil and air cooled. Engineoil is circulated through the housing which acts as aheat barrier between the "hot" turbine and the "cold"compressor. The bearings are sleeve-type and arelubricated by engine oil. Oil is pumped directly fromthe crankcase and circulated in the turbochargerhousing. Then the oil is returned to the sump throughan oil drain in the turbocharger mounting pedestal.

NOTE: There are no external oil inlet or drain tubesfor the turbocharger. Oil is exchanged via machinedpassages in the crankcase and the turbochargermounting pedestal.

High velocity engine exhaust gases drive the turbineshaft assembly at rates up to 130,000 rpm. Filtered

air entering the compressor side of the turbochargeris compressed and delivered to the engine intakemanifold at a pressure greater than atmosphericpressure. Because more air is delivered to the intakemanifold, the net result is more power, improved fuelefficiency, and the ability to maintain power at higheraltitudes.

Some engines are equipped with an optional exhaustback pressure (EBP) device. This control devicehelps bring the engine up to its normal operatingtemperature at an increased rate. The deviceincreases the engine’s heat production by controllinga butterfly valve in the exhaust outlet housing. Whenthe exhaust is restricted by the butterfly valve, exhaustbackpressure increases, causing the engine to workharder in order to force out exhaust gases. The netresult is that the engine warms up at a much fasterrate. When the valve fully opens, the exhaust gasflows out unrestricted.



40 TURBOCHARGER

Figure 26 Standard Torque Non Wastegated Turbocharger, Late 1997 Model Year

1. Identification Tag2. Compressor Air Outlet3. Oil Cooled Center Housing4. Turbine Housing5. Exhaust Outlet

6. EBP Device7. Turbine Inlet8. EBP Regulator9. Compressor Housing10. Air Intake



TURBOCHARGER 41

Figure 27 Standard Torque, Non Wastegated Turbocharger 1998 Through Early 2000 Model Years(GTP-38 Model Shown)

1. Turbine Housing2. Compressed Air Outlet3. Air Intake4. Identification Tag5. Compressor Housing6. Turbocharger Pedestal

7. Exhaust Back Pressure Solenoid8. Oil Cooled Center Housing9. Optional Exhaust Back Pressure

Valve10. Exhaust Outlet



42 TURBOCHARGER

Figure 28 Standard Torque Wastegated Turbocharger Late 2000 Through 2003 Model Years (GTP-38Model Shown)

1. Oil Cooled Center Housing2. Wastegate Actuator3. Compressed Air Outlet4. Air Intake

5. Identification Tag6. Compressor Housing7. Pedestal8. Exhaust Back Pressure Solenoid

9. Exhaust Back Pressure Linkage10. Turbine Housing11. Exhaust Outlet



TURBOCHARGER 43

Figure 29 High Torque Wastegated Turbocharger, 1997 Through 2003 Model Years (GTP-37 ModelShown)

1. Identification Tag2. Compressed Air Outlet3. Air Intake4. Compressor Housing5. Wastegate Actuator

6. Pedestal7. Wastegate Linkage8. Turbine Housing9. Exhaust Outlet



44 TURBOCHARGER

Figure 30 Standard Torque Turbocharger Piping and Components

1. Turbocharger2. Exhaust Inlet Adapter Clamp3. Turbocharger Oil Supply O-ring

(2)*4. Turbocharger Exhaust Inlet

Adapter5. Exhaust Tube Seal (2)6. Turbocharger Adapter Flange (2)7. Left Exhaust Tube

8. Exhaust Tube Flange (2)9. Right Exhaust Tube10. Turbocharger Oil Drain O-ring

(2)*11. Turbocharger Pedestal

Assembly12. Turbocharger Manifold Hose

Clamp (4)13. Turbocharger Manifold Hose (2)

14. Charge Air Cooling Tube andCrossover Pipe

15. Turbocharger CompressorOutlet Seal

16. Turbocharger CompressorOutlet Clamp

17. Elbow Clamp18. Turbocharger Air Inlet Elbow

Assembly

*One O-ring is between the pedestal and turbochargermounting pad, one O-ring is between the turbochargerand pedestal.



TURBOCHARGER 45

Figure 31 High Torque Turbocharger Piping and Components

1. Turbocharger2. Exhaust Inlet Seal3. Exhaust Inlet Clamp4. Turbocharger Exhaust Inlet

Adapter5. Exhaust Tube Seal (2)6. Turbocharger Adapter Flange (2)7. Left Exhaust Tube8. Right Exhaust Tube

9. Exhaust Tube Flange (2)10. Turbocharger Oil Drain O-ring

(2)*11. Turbocharger Oil Supply O-ring

(2)*12. Turbocharger Compressor

Outlet Clamp13. Turbocharger Compressor

Outlet Seal

14. Charge Air Cooling Tube andCrossover Pipe

15. Turbocharger Manifold HoseClamp (4)

16. Turbocharger Manifold Hose (2)17. Elbow Clamp18. Turbocharger Air Inlet Elbow

*One O-ring is between the pedestal and turbochargermounting pad, one O-ring is between the turbochargerand pedestal.



46 TURBOCHARGER

Bellows Exhaust System Feature

Figure 32 Emission Label Location

1. Emission Label2. Left Side of Engine

NOTE: The Standard Torque engine is identifiedas T 444E. The High Torque engine is identified asT 444E HT.

The bellows exhaust system feature can be usedon all International® T 444E Standard Torque andHigh Torque engines. All the information requiredfor ordering the service kit is found on the exhaustemission label affixed to the left hand side valvecover. The following information is needed prior todetermining which service kit to order:

• Rating

• Model year

• Horsepower rating

Service Kits For Standard Torque Engines

Figure 33 Standard Torque Emission Label

1. International T 444E Engine Family Identification2. Horsepower and Torque Ratings

Beginning with serial number 1573357 all StandardTorque International® T 444E engines are equippedwith the bellows exhaust system. To add the bellowsexhaust feature to a standard torque engine, matchthe model year and engine serial number to thecorresponding service kit number listed.

The standard torque engine has the following ratings:

• 160 HP

• 175 HP

• 190 HP

• 195 HP

• 210 HP

After the horsepower rating of the standard torqueengine has been identified, compare the standardtorque engine serial number to the table below.

Table 3 Bellows Exhaust Service Kits forStandard Torque International® T 444E Engines

Model Year Serial NumberRange

Bellows ServiceKit Number

1994–1998 Prior to 843990 1843486C91

1999 and up 843990 and up 1837872C93



TURBOCHARGER 47

Service Kits for High Torque Engines

Figure 34 High Torque Emission Label

1. International® T 444E HT (High Torque) EngineFamily Identification

2. Horsepower and Torque ratings

The bellows exhaust system feature can be added toany high torque engine, use service kit 1833800C91.The high torque engine has the following horsepowerratings:

• 210 HP

• 215 HP

• 230 HP

• 250 HP

RemovalStandard Torque Turbocharger

Figure 35 Removing Road Draft Tube MountingBolts

1. Road Draft Tube Mounting Bolts (2)2. Road Draft Tube

1. Remove the two bolts securing the road draft tubeto the crankcase. Relocate road draft tube to gainaccess to the left side of the engine.



48 TURBOCHARGER

Figure 36 Removing Air Inlet Elbow

1. Turbocharger2. Air Inlet Elbow Clamp3. Air Inlet Elbow4. Crankcase Breather5. Road Draft Tube

2. Loosen the air inlet elbow clamp and remove theair inlet elbow from the turbocharger.

3. Remove exhaust pipe between the turbochargerand the muffler.

Figure 37 Removing Turbocharger Air ChargingTube/Crossover Pipe Assembly

1. Turbocharger Compressor Outlet Seal2. Turbocharger Compressor Outlet Clamp3. Charge Air Cooling Tube / Crossover Pipe Assembly4. Turbocharger Intake Manifold Hose5. Hose Clamp(s)

4. Remove the turbocharger charge air coolingtube/crossover pipe as follows:

a. Loosen the four hose clamps (two per side)that secure the hoses to the air intake covers.The clamps are located on the manifoldhoses.

b. Loosen the turbocharger compressor outletclamp that secures the charge air cooling tubeto the turbocharger compressor housing.

c. Remove the charge air cooling tube/crossoverpipe assembly.

d. Remove the turbocharger outlet seal from thecompressor housing.

e. Place protective caps onto the air intakemanifolds.

Figure 38 EBP Wiring Harness Connection

1. Wiring Harness Clip2. EBP Wiring Harness Connector

5. Disconnect the EBP electrical connector from thewiring harness, if equipped.



TURBOCHARGER 49

Figure 39 Removing Turbocharger From InletAdapter, Late 1997 Model Year Engine WithoutExhaust Bellows Feature Shown

1. Turbocharger Compressor Housing2. Retaining Bolts (2)3. Gasket4. Exhaust Inlet Adapter5. Studs On Inlet Adapter (2)

6. Late 1997 Model Year, Engines WithoutExhaust Bellows Feature: Remove tworetaining bolts and the two retaining nuts atthe exhaust inlet adapter to the turbine housingflange. Save these two retaining bolts. They willbe reused in the assembly procedure. Discardthe two retaining nuts.

7. Late 1997 Model Year, Engines With ExhaustBellows Feature: Remove four retaining bolts atthe exhaust inlet adapter to the turbine housingflange. Save these four retaining bolts. They willbe reused in the assembly procedure.

Figure 40 Removing Exhaust Inlet Adapter fromTurbocharger, Engine With Exhaust BellowsFeature Shown (1998 through 2003 Model Years)

1. Exhaust Inlet Adapter2. Clamp

8. Loosen and save turbocharger V-band clamp.Remove seal, if equipped.

Figure 41 Disconnecting EBP Piston Rod (1998through 2003 Model Years)

1. EBP Piston Rod2. Control Arm3. Slide Lock

9. Move the slide lock back and disconnect the EBPpiston rod from the control arm.

10. Late 1997 Model Year Only:Remove the boltssecuring the pedestal to the crankcase. Removethe turbocharger and pedestal assembly from theengine.



50 TURBOCHARGER

Figure 42 Removing Turbocharger MountingBolts (1998 through 2003 Model Years)

11. 1998 through 2003 Model Years: Removeand save the two turbocharger mounting bolts.Remove turbocharger from the pedestal by liftingthe turbocharger up.

Figure 43 Removing Pedestal and O-rings (1998through 2003 Model Years)

1. Mounting Bolts2. Oil Supply and Oil Drain O-rings

12. 1998 through 2003 Model Years: Remove theoil supply and oil drain O-rings from the pedestal.Remove four mounting bolts securing the pedestalto the crankcase and remove the pedestal fromthe engine.

Figure 44 Turbocharger Oil Supply and Oil DrainPorts

1. Oil Supply O-Ring2. Oil Drain O-Ring3. Turbocharger Mounting Pad

13. Remove and discard the two O-rings located onthe turbocharger mounting pad. Cover openingsafter removal.

Figure 45 Turbocharger Openings to be Capped(Late 1997 Model Year Shown)

1. Exhaust Outlet2. Turbocharger Exhaust Inlet3. Turbocharger Oil Inlet and Oil Drain Ports4. Turbocharger Air Inlet5. Turbocharger Air Outlet

14. Cap all turbocharger openings to preventcontamination. If plastic caps are not available,use duct tape to cover openings.



TURBOCHARGER 51

Figure 46 Removing Right Exhaust TubeMounting Hardware at Exhaust Manifold

1. Right Exhaust Tube2. Exhaust Tube Bolt3. Nut4. Right Exhaust Manifold

15. Remove two nuts and bolts from right exhaustmanifold. These bolts secure the right exhausttube to the exhaust manifold.

Figure 47 Removing Left Exhaust TubeMounting Hardware at Exhaust Manifold

1. Left Exhaust Tube2. Exhaust Tube Bolt3. Left Exhaust Manifold4. Nut

16. Remove two nuts and bolts from left exhaustmanifold. These bolts secure the left exhausttube to the exhaust manifold.

17. Remove the turbocharger exhaust tube assemblyfrom the engine.



52 TURBOCHARGER

High Torque Turbocharger

1. Remove air cleaner and pipe to the turbochargercompressor inlet.

2. Remove exhaust pipe between the turbochargerand the muffler.

Figure 48 Road Draft Tube Mounting Hardware

1. Mounting Bolts

3. Loosen and remove the two bolts securing theroad draft tube to the back of the crankcase.Relocate road draft tube to gain access to the leftside of the engine.

Figure 49 Removing Charge Air CoolingTube/Crossover Pipe Assembly

1. Crossover Pipe2. Charge Air Cooling Tube3. Hose Clamps4. Turbocharger Manifold Hoses5. Turbocharger Compressor Outlet Seal6. Turbocharger Compressor Outlet Clamp

4. Remove turbocharger charge air coolingtube/crossover pipe assembly as follows:

a. Loosen the four hose clamps (two per side)that secure the hoses to the air intake covers.The clamps are located on the manifoldhoses.

b. Loosen the turbocharger compressor outletclamp that secures the charge air cooling tubeto the turbocharger compressor housing.

c. Remove the charge air cooling tube/crossoverpipe assembly and the two manifold hoses.

d. Remove the turbocharger compressor outletseal from the compressor housing.

e. Place protective caps onto the air intakemanifolds.

5. Remove and save turbocharger V-band clampthat secures the turbocharger to the exhaustoutlet adapter. Remove seal.

6. Loosen and remove the two bolts that securethe turbocharger to the pedestal. Remove theturbocharger from the pedestal by lifting up.



TURBOCHARGER 53

NOTE: The turbocharger and pedestal must beremoved separately from the engine.

7. Remove and discard the oil supply O-ring andoil drain O-ring located on the underside of theturbocharger or on the top of the pedestal.

8. Remove the four flange head mounting bolts thatsecure the pedestal to the crankcase. Removethe pedestal.

Figure 50 Turbocharger Oil Supply and Oil DrainPorts


9. Remove and discard the two O-rings located onthe turbocharger mounting pad.

10. Cap all openings on the turbocharger assembly.If plastic caps are not available, use duct tape tocover openings.

Figure 51 Turbocharger Exhaust Tube MountingHardware (Right Side Shown)

1. Right Exhaust Tube2. Exhaust Tube Mounting Bolt3. Exhaust Tube Mounting Nut4. Right Exhaust Manifold

11. Remove the exhaust tube mounting hardware atthe left and right exhaust manifolds. Remove theexhaust inlet adapter and tube assemblies fromthe engine.



54 TURBOCHARGER

CleaningNOTE: Do not use a caustic solution on theturbocharger or its related components.

Turbocharger

1. Use a suitable solvent and nylon brush to cleanthe turbocharger, pedestal, EBP control valve (ifequipped), charge air cooling tube/crossover pipeand hoses. Use filtered compressed air to dry theparts.

2. Inspect the oil inlet and oil drain ports forrestrictions. Clean as required.

Related Components

1. Thoroughly clean the piping that connects the aircleaner to the turbocharger with soap and water.Use filtered compressed air to dry the piping.

2. Before cleaning the inside of the air cleanerelement housing, remove the vehicle-mounted aircleaner. Cleaning helps to prevent failure of theturbocharger or engine.

Disassembly (Standard TorqueOnly)Remove EBP Control Valve

Figure 52 Removing EBP Control Valve (Late1997 Model Year Shown)

1. EBP Control Valve Mounting Bolt (3)2. EBP Control Valve Housing

Remove the mounting bolts and lift the EBP controlvalve housing from the turbocharger.

Remove Turbocharger Pedestal

NOTE: Late 1997 Model Year, the turbocharger andpedestal are removed from the crankcase as anassembly. 1998 Model Years and up, the pedestaland turbocharger are removed separately.



TURBOCHARGER 55

Figure 53 Removing Pedestal Mounting Bolts(Late 1997 Model Year Only)

1. Pedestal2. Mounting Bolts3. Turbocharger

1. Once the turbocharger and pedestal assemblyhave been removed from the crankcase, removefour turbocharger pedestal mounting bolts fromthe bottom of the pedestal.

Figure 54 Turbocharger Pedestal

1. Solenoid Valve2. O-Ring Locations (2)3. Pedestal

2. Remove and discard the O-rings which seal theoil passages to the turbocharger.

3. Remove the solenoid valve from the pedestal, ifnecessary.

InspectionCheck Exhaust Inlet Adapter/Exhaust TubeMating Surface

NOTE: This procedure should only be done ifthe standard exhaust tubes are being changed toexhaust tubes with bellows. If you are not changingthe exhaust tubes or already have exhaust tubeswith bellows on the engine, DO NOT perform thisinspection.

Figure 55 Exhaust Inlet Adapter/Exhaust TubeGasket Mating Surface Dimension, Late 1997Model Year and Up



56 TURBOCHARGER

WARNING: To avoid serious personalinjury, possible death, or damage to theengine or vehicle, measure and inspectthe exhaust tube mating surface of theexhaust inlet adapter. The adapter musthave sufficient gasket support surface. Ifthe width of the gasket surface (X widthdimension of the figure above) on the inletadapter measures less than 5 mm (0.19 inch)a tight seal will not be formed between theinlet adapter and the exhaust tube, causingan exhaust leak. If the gasket mating surfacedoes not meet the minimum width, a newadapter must be ordered.

Late 1997 Model Year Only: Order exhaustturbo inlet adapter 1818163C1.

1998 Model Year Only: Order exhaust turboinlet adapter 1826618C91.

1999 and UP Model Years: Order exhaustturbo inlet adapter 1828540C91.

Compressor Impeller, Turbine Wheel andTurbocharger Pedestal

1. Inspect the compressor impeller and turbinewheel for blade erosion, bending, breakageor deposits. Replace the entire turbochargerassembly if any blades are damaged.

Deposits on the compressor impeller, and turbinewheel can be caused by the following conditions:

• High air inlet restriction allows oil to betransferred from the turbocharger centerhousing, resulting in oil deposits.

• Excessive oil consumption can result inturbine wheel carbon deposits.

• Engine overfueling can result in excessiveoperating temperatures, which can causealuminum components to melt. Such depositsmay be found on the turbine wheel if such afailure occurs.

Figure 56 Checking for Turbine/CompressorHousing Wheel Rubbing

2. Set the turbocharger on a work bench with theshaft in a horizontal position. Rotate the shaft andcheck for any wheel rubbing within the housings.The wheels must spin freely when turned by hand.

3. Inspect the turbocharger pedestal for cracks, wornspots and other damage.

Check Axial End Play

Figure 57 Checking Axial End Play

1. Dial Indicator2. Turbine Housing

1. With the turbocharger in a stable position, placethe tip of a dial indicator inline with the end of theturbine shaft. Reset the dial indicator to zero.



TURBOCHARGER 57

2. Move the shaft back and forth by hand andrecord the readings. If the readings exceedspecifications, the turbocharger must be replaced.

Rebuild EBP Piston Rod Assembly

Figure 58 EBP piston rod kit contents

1. Oil supply O-ring (2)2. Oil drain O-ring (2)3. Retaining ring4. End cover with O-ring5. Piston rod assembly6. Jam nut7. Latch end with slide lock

If oil is leaking from the EBP piston rod housing,installing the service kit may eliminate the need toreplace the entire turbocharger pedestal.

Figure 59 Different Turbocharger Pedestals

1. Hourglass-shaped pedestal2. Blocked-shaped pedestal

NOTE: Different shapes of pedestals are used on theT 444E engines. The service kit CAN NOT be usedon engines having S/N 843990 — 1825359 and usinghourglass-shaped pedestals. If oil is leaking fromthe EBP piston rod housing on these pedestals, theentire pedestal assembly must be replaced with P/N1831455C92.

Hourglass pedestals are still being used on someengines built after S/N 1825359. The service kit canbe used on those later engines.

Turbocharger assembly P/N 1831774C93 alreadyuses the new EBP piston rod assembly and can beserviced with this kit. The turbocharger part numberis located on the identification tag attached to theturbocharger compressor housing.

The different pedestals can be identified by thefollowing characteristics while installed on the engine:

Figure 60 Block-shaped Pedestal Installed

1. Turbocharger part number (location)2. Visible ledge3. Solenoid valve deeper

The block-shaped pedestal has a visible ledge wherethe turbocharger mounts to the pedestal. Also, thesolenoid valve installed in the pedestal, is set deeperinto the pedestal than in the hourglass shaped one.



58 TURBOCHARGER

Figure 61 Hourglass-shaped Pedestal Installed

1. Turbocharger part number (location)2. No visible ledge3. Solenoid valve protrudes

The hourglass-shaped pedestal does not have avisible ledge where the turbocharger mounts to thepedestal. The solenoid valve installed in the pedestalprotrudes out farther than in the hourglass shapevalve.

If leakage is visible from the EBP piston rod housing,install a new EBP piston rod assembly as follows:

Figure 62 EBP Piston Rod Housing

1. Latch End with Slide Lock2. Jam Nut (not included on production units)3. Piston Rod4. Pedestal5. End Cover6. Retaining Ring

1. Unscrew the latch (and jam nut, if equipped) fromthe end of the piston rod. Hold the piston rodsecurely while unscrewing the latch because it iscrimped to the piston rod.

2. Remove the retaining ring from the housing.

3. Remove the end cover from the housing by gentlytapping on the threaded end of the piston rod.

4. Remove the piston rod, spring, spring seatand two wiper seals (one black, one white) asan assembly from the housing. Discard theassembly.

5. Thoroughly clean and inspect the pedestal andthe inside of the housing.

6. Lubricate the inside of the housing and the outsideof the new EBP piston rod assembly with clean oil.

7. Install the new EBP piston rod assembly (withoutthe jam nut and latch) into the housing far enoughto install the cover and retaining ring.

8. Lubricate the O-ring on the new end cover withclean oil. Install the end cover and retaining ringin the housing.

9. Install a new jam nut, slide lock and latch on thethreaded end of the piston rod.



TURBOCHARGER 59

Check Wastegate Actuator

Figure 63 Checking Wastegate Actuator (hightorque model shown)

1. Magnetic Base2. Dial Indicator3. Wastegate Actuator4. Air Pressure Regulator5. Wastegate Actuator Shaft

1. Place the turbocharger on a flat surface. Positiona dial indicator with a magnetic base next to theturbocharger. Place the tip of the dial indicatorinline and at the end of the wastegate actuatorshaft. Reset the indicator needle to zero.

2. Use a hose and appropriate fittings to connect theregulated shop air hose to the wastegate actuator.

3. Connect an air hose to a shop air pressureregulator. Adjust the air pressure as specified inTable 4. Temporarily close off the air supply to letthe air pressure gauge return to zero.

4. Gradually apply shop air pressure to achieve theair pressure indicated in Table 4. Record thereading on the dial indicator.

5. If the reading does not meet specifications, thewastegate actuator must be replaced.

Assembly (Standard Torque Only)Install Turbocharger Pedestal

NOTE: Late 1997 Model Year, the turbocharger andpedestal are removed from the crankcase as anassembly. 1998 Model Years and up, the pedestaland turbocharger are removed separately.

Figure 64 Attaching the Turbocharger to thePedestal (Late 1997 Model Year Shown)

1. Turbocharger Pedestal2. Pedestal Mounting Bolts3. Turbocharger

1. If removed, install the solenoid valve and tightenthe mounting bolt.

2. Lubricate and install new oil supply and oil drainO-rings onto the pedestal.

3. Apply Never-Seez™ to the threads of the fourmounting bolts. Install and tighten the mountingbolts to the special torque value.



60 TURBOCHARGER

Install EBP Control Valve

Figure 65 Installing EBP Control Valve (Late1997 Model Year Shown)

1. EBP Control Valve Housing Bolts2. EBP Control Valve Housing

1. Align the bolt holes of the EBP control valvehousing and turbine housing.

2. Apply Never-Seez® to the threads of the EBPcontrol valve mounting bolts. Install and tightenthe mounting bolts to the special torque value.

3. Connect the EBP piston rod to the control arm.

Figure 66 Testing Control Rod Preload (Late1997 Model Year Shown)

1. Turbocharger2. EBP Control Valve3. Turbocharger Pedestal4. Jam Nut5. Spring Scale Tester

4. Check the EBP piston rod preload on a workbenchas follows:

a. Temporarily install the turbocharger onto thepedestal. Install the turbocharger mountingbolts finger tight.

b. Connect the EBP piston rod to the controlarm.

c. To determine when the EBP control valvemoves, insert a 0.01 in feeler gauge betweenthe control valve stop and the stop on theturbocharger housing.

d. Attach a spring scale tester to the control armand pull on the tester. When the feeler gaugefalls out, take the reading on the spring scaletester.

The reading on the spring scale tester shouldbe 13 N (10 lbf) when the feeler gauge fallsout.

e. If the preload of the EBP piston rod does notmeet this specification, shorten or lengthenthe piston rod by screwing the latch end in orout. Repeat the test procedure.



TURBOCHARGER 61

f. Lock the jam nut against the latch end whenthe proper preload is achieved.

g. Disconnect the EBP piston rod from thecontrol arm. Be careful not to turn the latchend of the piston rod.

h. Continue on as follows:

• Late 1997 Model Year Only: Theturbocharger and pedestal assemby canremain assembled. Proceed on to theInstallation procedure.

• 1998 Model Years and Up: Remove theturbocharger from the pedestal.

InstallationStandard Torque Turbocharger

NOTE:

A. Use anti-seize compound on the mountingbolts and all other bolt threads used on theexhaust system to prevent high temperaturecorrosion.

B. The same installation procedure is usedfor either engines equipped with or withoutthe exhaust bellows feature, except whereindicated.

1. Pre-assemble the right and left side tubeassemblies to the exhaust inlet adapter with theexhaust flange gasket (either side up) mountedbetween the exhaust tube flange and the exhaustinlet adapter. Torque the exhaust inlet adapterflange bolts that secure the exhaust tubes to theexhaust inlet adapter to the special torque value.

Figure 67 Installing Right Exhaust TubeMounting Hardware at Exhaust Manifolds

1. Right Exhaust Tube2. Exhaust Tube Bolt3. Nut4. Right Exhaust Manifold

Figure 68 Installing Left Exhaust Tube MountingHardware at Exhaust Manifolds

1. Left Exhaust Tube2. Exhaust Tube Bolt3. Left Exhaust Manifold4. Nut

2. Locate the reassembled exhaust inlet adapterand tube assembly into position and securethe exhaust tube assembly to the left and right



62 TURBOCHARGER

exhaust manifolds. Finger tighten the mountinghardware.

3. Remove all protective caps or duct tape from theturbocharger, pedestal and crankcase openings.

Figure 69 Turbocharger Oil Supply O-Ring andOil Drain O-Ring


4. Apply a light coat of grease to a new oil supplyO-ring and oil drain O-ring. Install the O-rings onthe turbocharger mounting pad.

5. Late 1997 Model Year Only:

A. Place the turbocharger and pedestalassembly onto the mounting pad.

B. Align the pedestal mounting holes withthe holes in the mounting pad.

C. Install the pedestal mounting bolts andtighten to the special torque value.

6. 1998 and Up Model Years:

A. Place the pedestal on the mounting pad.Make sure the bolt holes in the pedestalare aligned with the bolt holes in themounting pad. Install and tighten the fourflange head mounting bolts to the specialtorque value.

B. Apply a light coat of grease to a new oilsupply O-ring and oil drain O-ring. Installthe O-rings onto the pedestal.

Figure 70 Installing Turbocharger To Pedestal(1998 and UP Model Years Shown)

7. 1998 and UP Model Years:

A. Place the turbocharger on the pedestal.Make sure the bolt holes in theturbocharger are aligned with the boltholes in the pedestal.

B. Install and tighten the two turbochargermounting bolts to the special torquevalue.

Figure 71 Connecting EBP Piston Rod (1998and Up Model Years Shown)

1. EBP Piston Rod (Latch End)2. Control Arm3. Slide Lock



TURBOCHARGER 63

8. Connect the latch end of the EBP piston rod to thecontrol arm. Move the slide lock forward to securethe latch end to the control arm.

Figure 72 Installing Turbocharger To ExhaustInlet Adapter, Late 1997 Model Year EngineWithout Bellows Feature Shown)

1. Turbocharger Compressor Housing2. Retaining Bolts (4 for engines with exhaust bellows

tubes) (2 for engines without exhaust bellows tubes)3. Gasket4. Exhaust Inlet Adapter5. Studs On Inlet Adapter (Used on non exhaust

bellows application

9. Late 1997 Model Year, Engines WithoutExhaust Bellows Tubes:

A. Slide the turbocharger over the twomounting studs of the exhaust inletadapter.

B. Secure with two nuts and two retainingbolts. Tighten to the special torque value.

C. Tighten the exhaust tube mountinghardware at the exhaust manifolds to thespecial torque value.

10. Late 1997 Model Year, Engines With ExhaustBellows Tubes:

A. Slide the turbocharger over the exhaustinlet adapter and secure with fourretaining bolts. Finger tighten the bolts.

B. Tighten the bolts to the special torquevalue.


Figure 73 Installing the Exhaust Inlet Adapterto the Turbocharger (1998 and Up Model YearsShown)

1. Exhaust Inlet Adapter2. Clamp

11. 1998 and UP Model Years:

A. Install the exhaust inlet adapter on theturbocharger exhaust inlet. Make surethe dowel on the adapter aligns with thehole in the lip of the exhaust inlet.

B. Install and tighten the V-band clamp tothe special torque value.




64 TURBOCHARGER

Figure 74 Installing the EBP Wiring HarnessConnector (1998 and Up Model Years Shown)

1. Wiring Harness Clip2. EBP Wiring Harness Connector

12. Connect the wiring harness electrical connector tothe EBP solenoid.

Figure 75 Installing the Charge Air CoolingTube/Crossover Pipe Assembly

1. Turbocharger Compressor Outlet Seal2. Turbocharger Compressor Outlet Clamp3. Charge Air Cooling Tube/Crossover Pipe Assembly4. Turbocharger Intake Manifold Hose (2)5. Hose Clamp (4)

13. Remove protective caps from the air intakemanifolds.

14. Lubricate a new compressor outlet seal with cleanoil. Install the seal in the turbocharger compressoroutlet.

15. Install the charge air cooling tube/crossover pipeassembly as follows:

a. Install the charge air cooling tube/crossoverpipe assembly to the turbochargercompressor housing and air intake hoses.

b. To secure the charge air cooling tube to theturbocharger compressor housing, tighten theturbocharger compressor outlet clamp.

c. Tighten the four hose clamps (two per side)to secure the hoses to the air intake manifoldcovers.

Figure 76 Installing Air Inlet Elbow

1. Turbocharger2. Air Inlet Elbow Clamp3. Air Inlet Elbow4. Crankcase Breather5. Road Draft Tube

16. Install the air inlet elbow. Tighten the clamp.

17. Install and secure the exhaust pipe connecting theturbocharger to the muffler.



TURBOCHARGER 65

Figure 77 Install Road Draft Tube MountingBolts (Engine With Exhaust Bellows FeatureShown)

1. Road Draft Tube Mounting Bolt2. Road Draft Tube

18. Move the road draft tube into the correct position.

19. Install road draft tube mounting bolts and secureto crankcase. Tighten bolts to standard torquevalue.

High Torque Turbocharger

NOTE: Use anti-sieze compound on the mountingbolts and all other bolt threads used on the exhaustsystem to prevent high temperature corrosion.

1. Pre-assemble the right and left side tubeassemblies to the exhaust inlet adapter with theexhaust flange gasket (either side up) mountedbetween the exhaust tube flange and the exhaustinlet adapter. Torque the exhaust inlet adapterflange bolts that secure the exhaust tubes to theexhaust inlet adapter to the special torque value.

Figure 78 Turbocharger Exhaust Tube MountingHardware (Right Side Shown)

1. Right Exhaust Tube2. Exhaust Tube Mounting Bolt3. Exhaust Tube Mounting Nut4. Right Exhaust Manifold

2. Locate the reassembled exhaust inlet adapterand tube assembly into position and securethe exhaust tube assembly to the left and rightexhaust manifolds. Finger tighten the mountinghardware.

3. Remove all protective caps or duct tape from theturbocharger, pedestal and crankcase openings.

Figure 79 Turbocharger Oil Supply O-Ring andOil Drain O-Ring




66 TURBOCHARGER

4. Apply a light coat of grease to a new oil drainO-ring and oil supply O-ring. Install the O-ringsinto the turbocharger mounting pad.

5. Install the turbocharger pedestal on thecrankcase. Make sure the bolt holes in thepedestal align with the bolt holes in the crankcase.Install and tighten the flange head mounting boltsto the standard torque value.

6. Install new oil supply and oil drain O-rings on thetop of the pedestal.

7. Align oil supply and drain ports and placeturbocharger on the pedestal. Install the twomounting bolts and tighten them to the specialtorque valve.

8. Install the seal and align the exhaust inlet adapterwith the turbine inlet. Install the V-band clamp andtighten to the special torque value.

9. Tighten the exhaust tube mounting hardware atthe exhaust manifolds to the special torque value.

Figure 80 Installing Charge Air CoolingTube/Crossover Pipe Assembly

1. Crossover Pipe2. Charge Air Cooling Tube3. Hose Clamps (4)4. Turbocharger Intake Manifold Hoses (2)5. Turbocharger Compressor Outlet Seal6. Turbocharger Compressor Outlet Clamp

10. Use clean engine oil to lubricate a newturbocharger compressor outlet seal. Installthe seal into the compressor housing.

11. Install the charge air cooling tube/crossover pipeassembly as follows:

a. Install the charge air cooling tube/crossoverpipe assembly to the turbochargercompressor housing and intake manifoldhoses.

b. To secure the charge air cooling tube to theturbocharger compressor housing, tighten theturbocharger compressor outlet clamp.

c. Tighten the four hose clamps (two per side)to secure the intake manifold hoses to the airintake manifold covers.

12. Install the air inlet elbow and clamp. Tighten theclamp.



TURBOCHARGER 67

Figure 81 Installing Road Draft Tube

1. Road Draft Tube Mounting Bolts

13. Place the road draft tube into the correct position.

14. Install the road draft tube mounting bolts in thecrankcase. Tighten the bolts to the standardtorque value.



68 TURBOCHARGER

SPECIFICATIONS

Table 4 Turbocharger Specifications

EBP Control Rod Spring Preload 13.5 ± 3 N (10 ± 2 lbf)

Turbine Shaft Axial End Play 0.02 - 0.10 mm (0.001 - 0.004 in)

Turbine Shaft Radial Movement (Play) 0.08 - 0.15 mm (0.003 - 0.006 in)

Wastegate Actuator Movement (StandardTorque Model) 1.016 mm @ 101.35 ± 3.45 kPa (0.04 in @ 14.7 ± 0.5 psi)

Wastegate Actuator Movement (High TorqueModel) 0.369 mm @ 131 kPa (0.015 in @ 19 psi)

Special Torque

Table 5 Turbocharger Special Torques

Air Inlet Hose Clamps 4 N·m (36 lbf·in)

Compressor Outlet Clamp 2 N·m (19 lbf·in)

Exhaust Back Pressure Valve to Turbine Housing Mounting Bolts 21-24 N·m (15-18 lbf·ft)

Exhaust Inlet Clamp 12 N·m (9 lbf·ft)

Exhaust Tube to Exhaust Inlet Adapter Flange Bolts 28 N·m (21 lbf·ft)

Exhaust Tube to Exhaust Manifold Flange Bolts 26 N·m (19 lbf·ft)

Intake Manifold Hose Clamps 3 N·m (30 lbf-in)

Turbocharger Pedestal to Crankcase Mounting Bolts 24 N·m (18 lbf·ft)

Turbocharger to Pedestal Mounting Bolts (Standard Torque Model) 47–51 N·m (34–37 lbf·ft)

Turbocharger to Pedestal Mounting Bolts (High Torque Model) 49 N·m (36 lbf·ft)


Table 6 Turbocharger Special Service Tools

OEM1028 Dial Indicator with Magnetic Base

ZTSE4293 Turbocharger Intake Shield

ZTSE4296 Turbocharger Intake Cap Set

ZTSE4230 Spring Tension Scale 0–34 N·m (0-25 lbf)



MANIFOLDS 69

Table of Contents

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73Left Exhaust Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73Right Exhaust Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73Left Intake Manifold Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74Right Intake Manifold Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74

Cleaning.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74

Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75Exhaust Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75Right Exhaust Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75Left Exhaust Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76Right Intake Manifold Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77Left Intake Manifold Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

Special Torque.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78




70 MANIFOLDS



MANIFOLDS 71

Figure 82 Intake Manifold Component Locations

1. Turbocharger Charge AirManifold (Crossover Pipe)

2. Hose Clamp (4)3. Turbocharger Manifold Hose (2)

4. Right Air Intake Cover5. Left Air Intake Cover



72 MANIFOLDS

Figure 83 Exhaust Manifold Components

1. Exhaust Manifold (Right)2. Exhaust Manifold Gasket (For

Service Only)

3. Exhaust Manifold (Left)4. EBP Tube Access Hole



MANIFOLDS 73

RemovalLeft Exhaust Manifold

1. Remove two bolts securing turbocharger exhausttube to exhaust manifold.

Figure 84 Removing the Left Exhaust Manifold

1. Exhaust Manifold2. Mounting Bolts

2. Remove eight mounting bolts securing exhaustmanifold to cylinder head. Remove exhaustmanifold and gasket, if equipped.

Right Exhaust Manifold

1. Remove two bolts securing turbocharger exhausttube to exhaust manifold.

Figure 85 Removing the EBP Sensor Tube

1. EBP Sensor Tube2. EBP Sensor Tube Nut3. Exhaust Manifold

2. If equipped, loosen EBP sensor tube nut and pulltube away from exhaust manifold.

Figure 86 Removing the Oil Level Gauge

1. Oil Level Gauge2. Nut3. Right Exhaust Manifold

3. Remove nut securing oil level gauge bracket tostud bolt. Remove oil level gauge.

Figure 87 Removing the Right Exhaust Manifold

1. Exhaust Manifold2. Mounting Stud Bolt (1)3. Mounting Bolt (7)

4. Remove seven mounting bolts and one studbolt that secure exhaust manifold to cylinderhead. Remove exhaust manifold and gasket, ifequipped.



74 MANIFOLDS

Left Intake Manifold Cover

NOTE: When removing the left or right intake manifoldcover be sure to do the following steps:

• Loosen compressor outlet clamp on charge aircooling and crossover pipe.

• Loosen the four turbocharger manifold hoseclamps on the left and right intake manifolds andslide turbocharger manifold hoses away frommanifold cover inlets.

• Remove charge air cooling and crossover pipeand turbocharger manifold hoses as an assembly.

• Remove turbocharger compressor outlet sealfrom turbocharger.

Figure 88 Left Intake Manifold Cover Bolts

1. Remove ten bolts securing intake manifold coverto cylinder head.

2. Using a RTV sealant cutting tool, cut aroundintake manifold cover.

3. Remove intake manifold cover from cylinder head.

Right Intake Manifold Cover

NOTE: If it is necessary to disconnect and removethe fuel filter, refer to “Fuel Filter Piping”, in the FuelSystem section.

1. Remove three bolts securing the fuel filtermounting bracket to the manifold cover.

Figure 89 Right Intake Manifold Cover SlottedBolt Hole

2. Loosen but do not remove last bolt at the slottedbolt hole.

3. Loosen and remove remaining intake manifoldcover bolts.

4. Using a RTV sealant cutting tool, cut around theintake manifold cover.

5. Slide intake manifold cover off cylinder head.

CleaningNOTE: Be sure to clean all RTV sealant from cylinderhead and manifold cover.

Manifolds may be cleaned with a suitable non-causticsolvent or steam cleaned.



MANIFOLDS 75

InspectionExhaust Manifold

1. Inspect cleaned exhaust manifolds for cracks.Replace the exhaust manifold as required.

Figure 90 Inspecting Exhaust Manifold forWarpage

1. Exhaust Manifold2. Straight Edge3. Feeler Gauge

2. To inspect exhaust manifold for warpage, placea straight edge against mounting surface andtry passing a 0.13 mm (0.005 in) feeler gaugebetween straight edge and mounting surface.

• If feeler gauge passes through, exhaust manifoldrequires a gasket. Attach a gasket to theexhaust manifold and proceed to the installationprocedure.

• If a gasket was previously used on the exhaustmanifold, the manifold may be machined tocompensate for warpage. A maximum of 0.25mm (0.010 in) material can be machined off tocorrect warpage.

InstallationNOTE: When installing exhaust manifolds, only useprevailing torque flanged-head bolts with interferencethread.

Right Exhaust Manifold

Figure 91 Installing the Right Exhaust Manifold

1. Exhaust Manifold2. Mounting Stud Bolt (1)3. Mounting Bolt (7)

1. Apply Never-Seez® to the threads of the bolts.

2. Install right exhaust manifold (with gasket ifrequired). Secure with seven mounting boltsand one stud bolt. Tighten bolts in the specifiedsequence to the special torque value.



76 MANIFOLDS

Figure 92 Installing the Oil Level Gauge

1. Oil Level Gauge2. Nut3. Right Exhaust Manifold

3. Install oil level gauge. Secure oil level gaugebracket to stud bolt with nut.

Figure 93 Installing the EBP Sensor Tube

1. EBP Sensor Tube2. EBP Sensor Tube Nut3. Exhaust Manifold

4. If equipped, install EBP sensor tube to exhaustmanifold and tighten nut.

5. Connect exhaust manifold to turbochargerexhaust tube. Tighten bolts to the special torquevalue.

Left Exhaust Manifold

Figure 94 Installing the Left Exhaust Manifold

1. Exhaust Manifold2. Bolt

1. Apply Never-Seez® to the threads of the manifoldbolts.

2. Install exhaust manifold (with gasket, if required).Secure with eight mounting bolts. Tighten boltsin the specified sequence to the special torquevalue.

3. Connect exhaust manifold to the turbochargerexhaust tube. Tighten bolts to the special torquevalue.



MANIFOLDS 77

Right Intake Manifold Cover

NOTE: After the left or right intake manifold covershave been installed, be sure to do the following steps:

• Inspect and if necessary replace, compressoroutlet seal.

• Install the compressor outlet seal.

• Align and install charge air cooling and crossoverpipe and turbocharger manifold hoses as anassembly.

• Secure charge air cooling and crossover pipe toturbocharger by tightening the compressor outletclamp.

• Secure turbocharger manifold hoses to left, rightor both intake manifold covers by tightening thefour clamps (two per each hose).

Figure 95 Right Intake Manifold Cover Bolts

1. Apply RTV sealant to mating surfaces of the intakemanifold cover.

2. Install intake manifold cover onto the cylinderhead. Make sure the slotted bolt hole slidesunder the installed bolt.

3. Place fuel filter mounting bracket onto intakemanifold cover. Secure with three mounting boltsand finger tighten.

NOTE: If the fuel filter needs to be installed andconnected to the fuel lines, refer to “Fuel Filter andPiping”, in the Fuel System section.

4. Install remaining manifold cover bolts and tightenall bolts in the specified sequence to the specialtorque value.

Left Intake Manifold Cover

Figure 96 Left Intake Manifold Cover Bolts

1. Apply RTV sealant to mating surfaces of the intakemanifold cover.

2. Install intake manifold cover onto the cylinderhead. Install ten manifold cover bolts and tightenall bolts in the specified sequence to the specialtorque value.



78 MANIFOLDS

SPECIFICATIONS

Table 7 Manifolds

Between ports: 0.13 mm (0.005 in)Maximum Allowable Warpage

Total: 0.25 mm (0.010 in)

Maximum Allowable Removal of Material 0.25 mm (0.010 in)

Special Torque

Table 8 Manifolds Special Torques

Intake Manifold Cover Bolts 24 N·m (18 lbf·ft)

Exhaust Manifold Mounting Bolts 61 N·m (45 lbf·ft)

Exhaust Manifold Flanges 28 N·m (21 lbf·ft)

Figure 97 Exhaust Manifold Mounting Bolt Torque Sequence

1. Start all exhaust manifold mounting boltsinto the holes by hand. Tighten all exhaustmanifold mounting bolts to 61 N·m (45 lbf·ft)in the numerical sequence shown.

2. Tighten all exhaust manifold mounting bolts to61 N·m (45 lbf·ft) again in an inline sequencefrom the rear to the front. Start at the arrow.



MANIFOLDS 79

Figure 98 Intake Manifold Mounting Bolt Torque Sequence

Start all intake manifold mounting bolts into the holesby hand. Tighten the mounting bolts to 24 N·m (18lbf·ft) in the numerical sequence shown.


Table 9 Manifolds Special Service Tools

OEM1028 Straightedge

ZTS4385 Intake Manifold Cover Removal Tool



80 MANIFOLDS



CYLINDER HEAD AND VALVES 81

Table of Contents

Cylinder Head Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84Remove Left Valve Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84Remove Right Valve Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84Disconnect Under Valve Cover Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85Remove Glow Plug.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85Remove Oil Director Spout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86Remove Valve Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86Remove Push Rod.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87Drain Fuel Gallery and Oil Rail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87Remove Fuel Injector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88Remove EBP and ICP Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90Remove Cylinder Head.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

Cleaning.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92Crankcase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92Cylinder Head.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92

Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92Check For Warp.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92Check Cylinder Head Thickness.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93Check Valve Recession. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

Surface Height Gauge Method.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93Straightedge and Feeler Gauge Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

Check for Valve Leakage (Using Mineral Spirits). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94Check for Cracks (Using Dye Penetrant). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94Cylinder Head Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96Refacing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

Valve Face. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97Valve Stem.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

Valve Guides. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98

Valve Seats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98Resurfacing.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98

Valve Springs.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100Cleaning.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100



82 CYLINDER HEAD AND VALVES

Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

Valve Rotators And Retainer Keys.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101Cleaning And Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101Testing Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

Fuel Injector Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102Cleaning Bores, Fuel Galleries and Oil Galleries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

Cylinder Head Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105Install Valve Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105Install Oil and Fuel Rail Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106

Oil Rail End Plug.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106Drain Plugs.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107Oil Gallery Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108

Valve Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108Cleaning.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109

Fuel Injector O-rings And Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111

Cylinder Head Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112Install Fuel Injector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113Install Oil Director Spout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114Install Push Rods.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114Install Valve Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115Install Glow Plug.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115Connecting Under Valve Cover Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115Installing Valve Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116

Crankcase Breather. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117Cleaning.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119

Special Torque.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120

Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122




Figure 99 Exploded View of Cylinder Head, Valves and Valve Cover Components

1. Oil Filler Standpipe2. Right Valve Cover3. Under Valve Cover (UVC)

Gasket (2)4. Right Intake Cover5. Lifting Eye (2)6. Left Valve Cover7. Valve Lever Assembly Mounting

Bolt (32)8. Intake Valve Lever Assembly (8)9. Exhaust Valve Lever Assembly

(8)

10. Valve Retainer Key (32)11. Valve Rotator (16)12. Valve Spring (16)13. Valve Seal (16)14. Intake Valve (8)15. Exhaust Valve (8)16. Pipe Plug (4)17. Cylinder Head (2)18. Cylinder Head Mounting Bolt

(36)19. Cylinder Head Plug (8)20. Fuel Injector Sleeve (8)

21. O-Ring (6)22. Oil Gallery Plug (6)23. Oil Rail Drain Plug (4)24. O-Ring (4)25. O-Ring (4)26. Oil Rail End Plug (4)27. O-Ring (4)28. Fuel Gallery Drain Plug (4)29. Coolant Expansion Cup Plug (4)30. Steel Ball (8)31. Cylinder Head Gasket (2)




Cylinder Head DisassemblyBefore removing the cylinder head, remove thefollowing items. Refer to the appropriate section forthe correct removal procedure:

• Fuel lines and filter assembly

• High pressure hydraulic lines

• Engine harness connections

Remove Left Valve Cover

CAUTION: To avoid damage to the engine,cover the turbocharger inlet port to eliminateinduction of debris.

1. Remove the crankcase breather elbow and roaddraft tube.

2. Disconnect the wiring harness from the UnderValve Cover (UVC) gasket.

Figure 100 Removing the Left Valve Cover

1. Mounting Bolt (10)2. Valve Cover

3. Remove valve cover mounting bolts. Remove thevalve cover from the cylinder head.

NOTE: The breather does not need to be removed atthis point.

Remove Right Valve Cover

1. Disconnect the wiring harness from the UVCgasket.

2. Remove the ECM and support bracket. SeeEngine Electrical section for the procedure.

Figure 101 Removing the Oil Filler Standpipe

3. Remove the oil filler standpipe from the valvecover.

Figure 102 Removing the Right Valve Cover

1. Mounting Bolt (4)2. Mounting Stud Bolt (6)3. Valve Cover

4. Remove the valve cover mounting bolts. Note thelocation of the stud bolts. Remove the valve coverfrom the cylinder head.




Disconnect Under Valve Cover Harness

Figure 103 Glow Plug Lead Connectors

1. Glow Plug Lead2. Glow Plug Lead Connector

CAUTION: To avoid damage to the wiringharness DO NOT pull on the wire leads whendisconnecting the connectors from the glowplugs and injectors.

1. Disconnect four glow plugs by pulling theconnectors away from the glow plugs. DONOT pull on the wire leads.

Figure 104 Disconnecting the Connector Fromthe Fuel Injector Solenoid

1. Connector2. Gasket Surface

2. Disconnect the solenoid connectors from the fuelinjectors by pushing the metal wire bail off thesolenoid and pulling the connector down.

Figure 105 Removing the Valve Cover Gasket

1. Gasket With UVC Harness2. Fuel Injector Solenoid Harness Connectors3. Glow Plug Leads

3. Remove valve cover gasket and the UVC wiringharness from the cylinder head.

NOTE: The valve cover gasket is reusable.

Remove Glow Plug

Figure 106 Removing the Glow Plug

Use a 10 mm (3/8 in.) deep socket, remove four glowplugs from each cylinder head.




Remove Oil Director Spout

Figure 107 Removing Oil Director Spout

1. Mounting Bolt2. Oil Director Spout3. Fuel Injector

Remove the mounting bolt and oil director spout fromeach of the fuel injector hold down clamps.

Remove Valve Lever

CAUTION: To avoid engine damage, markthe location of each intake and exhaustvalve lever assembly. The assemblies aredifferent and can be installed incorrectly ifnot properly marked.

Figure 108 Removing the Valve Lever Assembly

1. Valve Lever Assembly2. Mounting Bolt

Remove the valve lever mounting bolts. Lift the valvelever assemblies from the cylinder head.




Remove Push Rod

NOTE: BE SURE to mark each push rod so they canbe installed in their original position.

Figure 109 Removing Push Rods

Remove the push rods from the cylinder head.

Drain Fuel Gallery and Oil Rail

Figure 110 Front Fuel Gallery Drain Port

1. Fuel Gallery Drain Port2. Fuel Gallery Drain Plug

Figure 111 Rear Fuel Gallery Drain Port

1. Fuel Gallery Drain Plug

1. Drain the fuel gallery by removing the fuel gallerydrain plugs located at the front and rear of thecylinder head.




Figure 112 Oil Rail Drain Ports (two per head)

1. Oil Rail Drain Plug2. Oil Rail Drain Port

2. Drain the oil rail by removing the oil rail drain plugslocated under the valve cover in the high pressureoil rail.

Remove Fuel Injector

NOTE: Make sure the fuel rails and oil rails have beendrained before removing the fuel injectors.

Figure 113 Removing the Mounting Bolt for theFuel Injector Hold Down Clamp

1. Fuel Inboard Shoulder Bolt2. Fuel Injector Solenoid3. Mounting Bolt4. Fuel Injector Hold Down Clamp

1. Remove all mounting bolts from the outboard(exhaust manifold side) fuel injector hold downclamps.




Figure 114 Disengaging the Fuel Injector Hold Down Clamp

1. Shoulder Bolt 2. Fuel Injector Hold Down Clamp

CAUTION: To prevent damage to theshoulder bolt, make sure the fuel injectorhold down clamp is free of the shoulder boltwhen prying up on the clamp.

NOTE: The shoulder bolts on the inboard side are notaccessible and do not require removal.

2. Disengage the fuel injector hold down clamp fromthe inboard shoulder bolt by sliding the clamp upand away from the valve springs, then up and overthe head of shoulder bolt.

3. Use a fuel injector removal tool to remove the fuelinjector from the cylinder head bore. Install the "T"screw into the hold down clamp. Insert the fulcrumunder the outboard side of the hold down clamp.Turn the screw until the fuel injector is unseated.

Figure 115 Installing the "T" Screw Into the HoldDown Clamp

1. "T" Screw2. Hold Down Clamp3. Fuel Injector4. Fulcrum




Figure 116 Removing the Fuel Injector From theCylinder Head

1. Hold Down Clamp2. Fuel Injector3. Shoulder Bolt

4. Remove the fuel injector from the cylinder headbore by lifting the fuel injector straight up and out.Place the fuel injector in a fuel injector holder rack.

5. Remove the shoulder bolt (one per injector).

CAUTION: To avoid damage to the engine,always replace the O-rings and sealswhenever a fuel injector is removed. Referto the Fuel Injector O-Rings and Sealsprocedure in this section.

Remove EBP and ICP Sensors

NOTE: Before removing the left or right cylinder headdo the following:

• RIGHT CYLINDER HEAD — Disconnect andremove the EBP sensor and tube from the righthand exhaust manifold

• LEFT CYLINDER HEAD — Disconnect andremove the ICP sensor from the cylinder head.

1. Disconnect EBP sensor from wiring harness.

Figure 117 Removing the EBP Sensor

1. Bracket Mounting Bolt2. EBP Sensor3. EBP Sensor Tube4. EBP Sensor Tube Nut

2. Loosen EBP sensor tube nut at front of rightexhaust manifold. Disconnect tube from manifold.

3. Remove two mounting bolts that secure the EBPsensor bracket to the high pressure pump oilreservoir.

4. Remove EBP sensor, bracket, and tube as a unit.

5. Disconnect ICP sensor from the wiring harness.




Figure 118 Removing ICP Sensor

1. ICP Sensor2. O-Ring

6. Remove ICP sensor from left cylinder head.Discard O-ring.

Remove Cylinder Head

NOTE: Leave one mounting bolt installed at each endof the cylinder head. Remove the other mountingbolts. Cylinder head mounting bolts are flange headtype that do not require washers. All cylinder headmounting bolts are the same length.

Figure 119 Removing Cylinder Head MountingBolts

1. Loosen the mounting bolts evenly. Begin at eachend of the cylinder head and work toward themiddle.

Figure 120 Attaching the Lifting Bracket

1. Lifting Bracket2. Lifting Bracket Mounting Bolts (4)

2. Use four lifting bracket mounting bolts, securelifting bracket to the center of the cylinder head.

Figure 121 Removing Cylinder Head

1. Crankcase2. Lifting Bracket3. Cylinder Head

3. Attach a suitable lifting hook to the lifting bracket.Remove remaining two cylinder head mountingbolts.

4. Lift cylinder head squarely from the crankcaseand place it on a workbench.

5. Remove cylinder head gasket.




CleaningCrankcase

1. Clean the crankcase to cylinder head matingsurface of any gasket material, dirt, grease andany other foreign deposits.

CAUTION:

To avoid damage to the engine, clean dirtin threads or replace any damaged boltswith equivalent sized, phosphate coatedbolts with a 10.9 hardness grade. Damagedthreads may cause binding and result in afalse torque reading.

2. Use a bottoming hand tap (M12 x 1.75) to clear thecylinder head mounting bolt threads of all grease,dirt, and other deposits.

3. Wash all cylinder head bolts with a suitablesolvent and dry them thoroughly.

Cylinder Head

1. Remove lifting bracket from the cylinder head.

NOTE: When cleaning BE CAREFUL not to damagethe cylinder head gasket surface.

2. With valves installed to protect the seats, use arotary wire brush or gasket scraper with mineralspirits to remove any deposits and gasket materialfrom the gasket surface of the cylinder head.

3. Use a suitable solvent and brush to remove anydirt, grease and other deposits from all of the boltholes, oil return holes, water passages and fuelgalleries. Rinse thoroughly with hot water and drythe cylinder heads with filtered compressed air.

InspectionCylinder head condition must be evaluated bychecking all of the following conditions.

Check For Warp

Figure 122 Checking for Cylinder Head Warp

1. Straightedge2. Cylinder Head3. Feeler Gauge

Use a straightedge and feeler gauge to check thecylinder head gasket surface for warp.

If specifications are not met, check thickness of thecylinder head before resurfacing. The minimumdeck-to-deck dimension must be maintained afterresurfacing.




Check Cylinder Head Thickness

Figure 123 Checking the Cylinder HeadThickness

1. Outside Micrometer2. Cylinder Head

1. Refer to the left and right hand intake manifoldcover removal procedures, in the “MANIFOLDS”section.

2. Use a 5–6 inch outside micrometer, measurecylinder head thickness at six locations (fourcorners and two central points). If minimumdeck-to-deck dimension is not met, replacecylinder head.

Check Valve Recession

Surface Height Gauge Method

Figure 124 Checking for Valve Recession Usinga Surface Height Gauge

1. Set a surface height gauge on the cylinder headdeck. Zero dial indicator.

2. Move dial indicator onto the valve face. Recordreading. If specification is not met, valve orcylinder head may require repair or replacement.




Straightedge and Feeler Gauge Method

Figure 125 Checking for Valve Recession Usinga Straight Edge and Feeler Gauge

1. Straightedge2. Feeler Gauge

1. Place straightedge across valve.

2. Insert a feeler gauge of proper size betweenstraightedge and valve face. Record reading. Ifspecification is not met, valve or cylinder headmay require repair or replacement.

Check for Valve Leakage (Using Mineral Spirits)

1. Position cylinder head on wood blocks with thegasket surface facing down.

2. Squirt mineral spirits into intake and exhaustports.

3. Wait five minutes. Use an inspection mirrorto inspect valve seat area for any indication ofmineral spirits leakage.

There should be no leakage. Reconditioning is notrequired if the cylinder head passes this valve leakagecheck. If leakage is observed, the valves and seatsrequire reconditioning.

Check for Cracks (Using Dye Penetrant)

Figure 126 Checking the Cylinder Head ForCracks Using the Dye Penetrant Method

1. Gasket Surface of the Cylinder Head

1. Spray commercially available brake cleaner ontogasket surface of cylinder head. Wipe dry.

2. Spray on dye penetrant. Allow dye to remain for1–30 minutes.

3. Wipe dye off gasket surface. Dye will remain incracks.

4. Spray on developer. Let dry for 5–15 minutes.

Figure 127 Crack in Cylinder Head

5. Cracks show up as purple lines against whitedeveloper. If cracks are present, replace cylinderhead.




Cylinder Head Pressure Test

Pressure testing the cylinder head will reveal cracksin ports or sleeve leakage which cannot be observedusing the dye penetrant method.

1. Remove the valves. Refer to Valves, Removal forthe procedure.

Figure 128 Installing the Fuel Injector ShoulderBolts

1. Shoulder Bolt2. Cylinder Head

2. If removed, install the inboard injector shoulderbolts into the cylinder head. Tighten the bolts tothe special torque value

NOTE: Be careful not to damage the fuel injector tipsduring this procedure.

3. Install the fuel injectors into the cylinderhead injector bores. Refer to Cylinder HeadAssembly, Install Fuel Injectors for theprocedure.

Figure 129 Installing the Cylinder Head PressureTest Plate

1. Pressure Plate Mounting Bolts (18)2. Pressure Plate3. Pressure Gauge and Regulator

4. Remove the fitting or plug from the cylinderhead. Install the pressure test regulator/gaugeassembly.

5. Fasten the pressure plate and plate gasket to thecylinder head gasket surface with the mountingbolts and nuts supplied with the kit.

6. Spray a soapy water solution into all of the valvebores. Apply air pressure and adjust to 124-138kPa (18-20 psi). Check for leaks at the followinglocations:

• Ports

• Upper cylinder head deck

• Lower cylinder head deck

• Nozzle sleeve area

CAUTION: To avoid engine damage, replacethe cylinder head if leakage is observed atany port or at the upper or lower cylinderhead deck.




ValvesRemoval

Figure 130 Removing the Valve Retainer Keys

1. Valve Spring Compressor Tool2. Valve Spring3. Valve Assembly Retainer Keys

1. Use a valve spring compression tool to compressthe valve spring.

2. Use a small magnet to remove the valve assemblyretainer keys.

Figure 131 Removing the Valve Rotor andSpring

1. Valve Spring2. Valve Rotator

3. Remove the valve rotator.

4. Remove the valve spring.

Figure 132 Removing the Valve Seal From theValve Stem

1. Valve Seal2. Valve Stem

5. Remove the valve seal from the valve stem anddiscard.

6. Remove the valve from the cylinder head.

Cleaning

Use a suitable solvent and a fine brass wire brush toremove all carbon deposits from the valve stems andvalve heads.

Inspection

1. Inspect each valve. Replace any valves that showevidence of burn marks, warp, scuffing, bendingor tip pitting.

2. Measure the valve stem diameter at threelocations at 120 intervals. Replace any valvesthat do not meet the specification.

3. Use the measurements from Step 2 to determinethe valve stem-to-guide running clearance.Subtract the valve stem diameter from the valveguide inside diameter. Refer to Inspection,Valve Guides for the procedure to determine thevalve guide inside diameter. Replace the valvesthat exceed the specification.




Refacing

Valve Face

NOTE: Intake and exhaust valves have the same stemlength and diameter. However, the exhaust valve hasa dimple on the bottom of the valve.

Figure 133 Intake and Exhaust ValveComparison

1. Exhaust Valve (With Dimple)2. Intake Valve

1. Use a dressing stud attachment or grinder todress the cutting stone.

2. Place the valve in the grinder collet set to thespecified angle. Turn on the cutting oil.

CAUTION: To avoid engine damage, theminimum valve face margin must bemaintained across the entire valve face.An insufficient margin will not provideproper heat dissipation and will lead to valvewarp or breakage.

NOTE: Intake and exhaust valve margins and valveface angles are different. See the Specifications forthe correct measurements for each.

3. Grind the valve face. Remove only the minimumamount of material that is necessary to truethe valve face. Record the amount of materialremoved for later reference during valve stemresurfacing.

Figure 134 Measuring the Valve Face Margin

4. Use a caliper to measure the valve face margin atfour locations. Replace the valve if the margin isless than the specification after grinding.

Valve Stem

NOTE: Refacing the valve stem tip provides a newwear surface for the valve lever and compensates formaterial that was removed during the valve refacing.

1. Dress the cutting stone by moving the dressingstud attachment across the face of the cuttingstone until a uniform grinding surface is achieved.

2. Place the intake or exhaust valve into the valvestem clamping "V.” Turn on the cutting oil.

CAUTION: To avoid engine damage whenresurfacing the valve stem tip, leavesufficient material so the valve lever doesnot contact the valve spring, retainers, orrotators during operation.

3. Touch the valve stem tip to the cutting stone.Remove only a minimum amount of material. Donot remove more material than was removed atthe valve face.




Valve GuidesCleaning

With the valves removed from the cylinder head, cleanall valve guides in a soap and water solution with anylon brush. Blow out any remaining residue withfiltered compressed air.

Inspection

1. Position an inspection light at the bottom of thevalve guide bores and examine the walls forburning or cracking. Replace the cylinder head ifit does not pass inspection.

Figure 135 Measuring the Valve Guide InsideDiameter

2. Measure each valve guide for wear. Use anappropriate sized small hole gauge to checkthe inside diameter of the valve guide at threelocations at the upper end and at the lower end.Measure the small hole gauge with a 0-1inchmicrometer. Record the readings.

If any valve guide inside diameter is over thespecification, replace the cylinder head.

Valve SeatsCleaning

Clean the valve seat area with a suitable solvent.

Inspection

Inspect the exhaust valve seats for wear or burnedspots. Either of these conditions require valve seatresurfacing. If a crack is found, the cylinder head mustbe replaced.

Resurfacing

Figure 136 Installing a Pilot in the Valve Guide

1. Pilot

1. Lightly lubricate and install the correct size pilotinto the valve guide bore.




Figure 137 Using a Grinding Stone

2. Choose the correct angle grinding stone anddress the stone.

3. Install the grinding stone over the pilot.

4. Lower the grinding head over the pilot shank untilthe wheel contacts the valve seat. Turn on thepower and gently apply the wheel to the valve seatwith hardly any pressure other than weight of thegrinding wheel itself.

5. Raise the wheel frequently to prevent overheating.

6. Grind the seat to a smooth even finish.

7. After grinding, use a caliper to check the widthof the valve seat. If the valve seat widths areexcessive, they may be corrected by grinding witha 15 or less angled stone.

NOTE: If a new valve does not correct an excessiverecession condition, replace the cylinder head. If thevalve face protrudes above the deck, the valve seatmust be ground deeper into the cylinder head. Aftergrinding a valve seat, check the seat width and confirmvalve seat contact by using Prussian Blue™.

8. After grinding the valve seat, use a depth gaugeand micrometer to check the valve recession.Valve recession should not exceed specifications.

9. After the valves have been resurfaced and thevalve guides have been cleaned, insert the valvesinto the clean valve guide. Check the contactbetween the valve face and valve seat usingPrussian Blue™ or equivalent as follows:

a. Spread a thin film of Prussian Blue on thevalve face. Insert the valve into its guide.

b. Apply pressure on the center of the valvehead while making a quarter turn into thevalve seat.

c. Remove the valve. Inspect the impressionmade on the valve seat and the valve face.

d. A blue line should appear around the entirecontact surface of the valve seat and animpression on the blue film of the valve faceshould be centered. Check several times toprevent error. If acceptable, proceed withvalve installation.

10. For proof of results of refacing and to test seatingoperations, recheck the valve recession. Referto Inspection, Check Valve Recession in thissection.

A poor quality grind cannot be corrected bylapping. Inspect each valve for seat dimensionsand make any necessary corrections. Correctionsshould always be made on the seat, not the valveface. If the recession is excessive, install a newcylinder head. If the valve protrudes above thedeck, grind the valve seat.




Valve SpringsCleaning

Clean all valve springs and valve retainer keys in asuitable solvent.

Inspection

1. Inspect the inside and outside of the valve retainerkeys for wear. Replace any worn retainer keys.

2. Inspect the valve springs for rust, pitting andcracks. Look for spring distortion.

Figure 138 Checking Free Length and Flatnessof the Valve Spring

3. Check the free length and flatness of the valvesprings. The spring ends must be flat and square.Springs that are out-of-square place a lateral loadon the stem, causing accelerated valve guidewear.

Figure 139 Checking the Valve Spring Tension

1. Linear Scale2. Valve Spring3. Load Indicator

4. Use a valve spring tester to measure the valvespring tension. Apply the appropriate test loadto each spring and refer to the specifications.Measure maximum spring length in use (valveclosed) and the minimum spring length in use(valve open).

5. Replace any valve spring that is rusted, pitted,cracked, bent or incapable of meeting thespecifications.




Valve Rotators And Retainer KeysCleaning And Inspection

1. Clean all rotators and retainer keys in a suitablecleaning solvent.

2. Inspect retainer keys for any damage or extrusion.Replace as sets if required.

Testing Operation

CAUTION: To avoid damage, lubricate therotator with clean engine oil before testingand reuse in the engine.

Figure 140 Testing Operation of Valve Rotators

1. Place valve spring and rotator in spring tester.Place a ball bearing between rotator and ram ofthe spring tester. The ball bearing must be largeenough to prevent the ram from touching any partof the rotator.

2. Paint a reference line on the rotator.

3. Compress the valve spring rapidly with evenpressure and observe the rotator as it turns.Replace any rotator that does not turn.




Fuel Injector SleeveRemoval

CAUTION: To avoid engine damage, whenremoving the fuel injector sleeve withoutremoving the cylinder head, place a corkplug into the bore before performing thefollowing procedure. This will prevent debrisfrom entering the cylinder bore.

Figure 141 Removing the Fuel Injector Sleeve

1. Fuel Injector Sleeve2. Fuel Injector Bore3. Fuel Injector Sleeve Removal Tool4. Centering Collar

1. Install the fuel injector removal tool into the fuelinjector sleeve.

2. Turn the removal tool to cut threads into the fuelinjector sleeve. Remove the tool from the bore.

Figure 142 Removing the Fuel Injector Sleeve

1. Slide Hammer2. Fuel Injector Sleeve Puller Tool

3. Install the fuel injector sleeve puller tool into thefuel injector sleeve and tighten the tool. Make surethe tool has been completely threaded into the fuelinjector sleeve.

Figure 143 Fuel Injector Sleeve Removed FromBore

1. Fuel Injector Sleeve Removal Tool2. Fuel Injector Sleeve3. Fuel Injector Bore

4. Thread the slide hammer into the fuel injectorsleeve removal tool. Remove the fuel injectorsleeve from the fuel injector bore.




Cleaning Bores, Fuel Galleries and Oil Galleries

Figure 144 Cleaning the Fuel Injector Bore

1. Injector Sleeve Bottom Brush2. Fuel Injector Bore

1. Insert the injector sleeve bottom brush into the fuelinjector bore to remove deposits and hardenedsealant from the bore.

Figure 145 Oil Rail End Plugs

1. Oil Rail End Plug (two per cylinder head)

2. Remove the two oil rail end plugs (one located ateach end of the cylinder head).

3. Insert a stiff nylon brush into the oil gallery.

Figure 146 Cleaning the Oil Galleries

1. Small Nylon Brush In Oil Gallery Port2. Oil Galley Port3. Fuel Injector Bore

4. Remove the three oil gallery plugs and the highpressure oil supply fitting. Insert a small stiff nylonbrush into each oil gallery.

Figure 147 Cleaning the Fuel Galleries

1. Small Nylon Brush In Fuel Gallery Port2. Fuel Injector Bore

5. Remove the two fuel gallery plugs. Insert a smallstiff nylon brush into each fuel gallery.




Figure 148 Cleaning the Fuel and Oil GalleriesWith Compressed Air

1. Oil Gallery2. Fuel Injector Bore3. Air Nozzle

6. Use filtered compressed air to clean out all debrisfrom the fuel and oil gallery ports.

Installation

Figure 149 Preparing the Fuel Injector Sleevefor Installation

1. Installation Tool2. Fuel Injector Sleeve3. Loctite® Application Area

1. Attach a new fuel injector sleeve to the installationtool. Apply Loctite® #262 to the fuel injector sleeveat the end and top.

2. Use installation tool to insert fuel injector sleeveinto fuel injector bore.

Figure 150 Inserting the Fuel Injector Sleeve

1. Installation Tool2. Fuel Injector Sleeve3. Hammer

3. Use a hammer to drive the fuel injector sleeve intothe fuel injector bore. Remove installation toolwhen fuel injector sleeve is in place.

4. Inspect the fuel injector sleeve after installation.Use a shop rag to remove any debris caused byinstallation.

The following cutaway shows fuel injector sleeveinstalled into the fuel injector bore. Note areas wherefuel injector sleeve lands contact the cylinder head.




Figure 151 Fuel Injector Sleeve Installed inCylinder Head

1. Fuel Injector2. Cylinder Head3. Loctite Application Area4. Fuel Injector Sleeve

Cylinder Head AssemblyInstall Valve Assemblies

NOTE: The exhaust valve stems have a dimple on thevalve head.

Figure 152 Lubricating the Valve Stems

1. Oil Can2. Exhaust Valve3. Intake Valve

1. Lubricate the valves with clean engine oil. Insertthe valve stems into their respective valve guidebores in the cylinder head.

Figure 153 Installing the Valve Seal

1. Valve Seal2. Valve Stem

2. Lubricate the inner diameter of the new valve stemseals with clean engine oil. Install the seals overeach valve stem. Make sure the seal assembly isseated against the cylinder head spring pockets.

Figure 154 Installing the Valve Rotators

1. Valve Spring2. Valve Rotator

3. Install the valve spring over the stem sealassembly.

4. Install the valve rotators.




Figure 155 Installing the Valve AssemblyRetainer Keys

1. Valve Spring Compression Tool2. Valve Spring3. Valve Assembly Retainer Key

5. Attach the valve spring compression tool andcompress the valve spring. Install the valveassembly retainer keys and release valve springcompression tool. Make sure the retainer keysare correctly seated on all valve stems.

6. After valve inspection, reconditioning andreplacement/installation, measure the valvehead recession relative to deck to confirm a goodreconditioning job. Refer to the specifications.

Install Oil and Fuel Rail Plugs

Oil Rail End Plug

Figure 156 New and Old Style Oil Rail End Plug

1. New Style Oil Rail End Plug With ID Groove2. Old Style Oil Rail End Plug Without ID Groove

1. Check the oil rail end plug for an identificationgroove. New style oil rail end plugs feature anidentification groove. Replace old style end plugwith new style end plug.

Figure 157 Oil Rail End Plugs

1. Oil Rail End Plug (two per head)

2. Use a clean dry cloth and brake cleaner toclean the cylinder head internal threads. Dry thethreads before installing the plug.

CAUTION: To avoid engine damage, makesure the threads of the oil rail end plugs arefree of any oily residue. Failure to do so mayresult in leakage past the plugs.

3. Apply clean engine oil to the seals. Install theseals onto the oil rail end plugs without getting oilon the clean threads.

4. Apply a small bead of Loctite® #277 around thethreads of the oil rail end plugs. Install the plugs.Tighten oil rail end plugs to the special torquevalue.

NOTE: Before engine operation, wait at least one hourfor the Loctite to cure.




Drain Plugs

CAUTION: To prevent engine damage, donot apply sealant to threads of the oil drainplugs. DO NOT use anti-sieze compounds,grease, or any other lubricant except engineoil. Other lubricants have an adverse effecton torque values.

Figure 158 High Pressure Oil Rail Drain Plug

1. Oil Rail Drain Plug (two per head)2. Torque Wrench3. Oil Rail End Plug

1. Apply clean engine oil to a new O-ring for each ofthe oil rail drain plugs (two per head).

2. Install the oil rail drain plugs into the cylinder headports. Tighten the oil rail drain plugs to the specialtorque value.

Figure 159 Location of Front Fuel Rail DrainPlug

1. Fuel Gallery Drain Port2. Fuel Gallery Drain Plug

Figure 160 Location of Rear Fuel Rail Drain Plug

1. Fuel Gallery Drain Plug

3. Apply clean oil to a new O-ring for both of the fuelrail drain plugs.

4. Install the two fuel rail drain plugs into the cylinderhead ports. Tighten the fuel rail drain plugs to thespecial torque value.




Oil Gallery Plugs

Figure 161 Installing the Oil Gallery Plugs

1. High Pressure Oil Supply Fitting2. Oil Gallery Plugs (three per head)3. Torque Wrench

1. Install new O-rings on the three oil gallery plugs.

2. Apply Loctite® #262 onto the threads of the threeoil gallery plugs and the one high pressure oilsupply fitting. Install the plugs and fitting into theoil gallery ports located above each of the fuelinjector bores. Tighten the plugs and fitting to thespecial torque value.

Valve Lever

Disassembly

Figure 162 Disassemble the Valve Lever

1. Valve Lever Clip2. Valve Lever Post3. Chrome Ball4. Valve Lever

NOTE: BE SURE to keep all items of each rocker levertogether for installation in their original locations.

1. Carefully remove the valve lever clip that securesthe valve lever, valve lever post, and the 10 mm(3/8 in) chrome ball.

2. Remove the chrome ball from the cup on the valvelever.

3. Separate the valve lever from valve lever post.

Cleaning

Clean all parts with a suitable solvent and dry partsusing filtered compressed air.




Inspection

Figure 163 Valve Lever Component Relationship

1. Retaining Clip2. Valve Lever Post3. Chrome Ball4. Valve Lever5. Valve Lever Assembly

1. Inspect the valve stem ends and correspondingvalve lever pads for pitting or scuffing. Inspectthe chrome ball and ball socket in valve lever forscuffing. Replace the levers as required.

2. Inspect the valve lever post ball socket forexcessive wear. Inspect the bolts for threaddamage. Replace worn components as required.

Assembly

Figure 164 Lubricating the Chrome Ball

1. Place the chrome ball on the valve lever cup.Lubricate the chrome ball with clean engine oil.

Figure 165 Installing the Valve Lever Post

2. Place the valve lever post on the chrome ball.

Figure 166 Installing the Retaining Clip




CAUTION: To avoid engine damage, installthe retaining clip correctly. Failure to do socould result in valve lever assembly comingapart in the running engine.

3. Snap the retaining clip over the valve lever postgroove.

Figure 167 Valve Lever Retaining Clip Position

1. Retaining Clip2. Valve Lever3. Valve Lever Post4. Pivot Ball

Fuel Injector O-rings And Seals

Removal

CAUTION: To avoid engine damage, all ofthe O-rings and seals on the fuel injectorshould be replaced anytime the fuel injectoris removed. When removing or installing theO-rings and seals, be careful not to scratchthe seal grooves of the fuel injector body.Use a non-metallic tool (wood or plastic) toremove the seals away from the grooves.Failure to do so could result in fuel or oildilutions.

1. Remove the copper gasket from the bottom of thefuel injector.

2. Lift the lower O-ring out of its groove. Cut andremove the seal.

3. Lift the middle seal out of its groove. Cut andremove the seal.

4. Lift the upper O-ring out of its groove. Cut andremove the seal.

5. Lift the upper cushion ring out of its groove. Cutand remove the seal.

6. Lift one corner of the backup ring from its groove.Slide the rest of the backup ring from its grooveand over the tip of the fuel injector.

7. Make sure the fuel injector is clean and free ofdebris. Place the fuel injector into a holder rackwhere it will be protected from debris and damage.




Installation

Figure 168 Fuel Injector O-Ring and Seal

1. Backup ring (Steel)2. Upper Cushion Ring3. Upper O-Ring Seal4. Middle Seal5. Lower O-Ring Seal6. Copper Gasket

CAUTION: To avoid engine damage, wheninstalling the O-rings and seals onto the fuelinjectors, make sure all O-rings and seals arelocated at the top of the grooves to preventthem from rolling during installation. Also,make sure the O-rings and seals do not twistduring installation. Failure to do so couldresult in fuel or oil dilution.

Upper Groove

1. Locate the upper grove seals.

2. Lightly lubricate the new upper groove seal withclean engine oil.

CAUTION: The backup rings acts like aspring. Be careful when installing thispart. Do not twist the ring. Ring flatness isimportant or a tight seal will not be formed.This could result in fuel or oil dilution.

3. Gently expand the ring. Slide the backup ring overthe body of the fuel injector and into the uppergroove.

4. Slide the cushion ring over the body of the fuelinjector. Push the cushion ring into the uppergroove. Make sure the cushion ring is against thebackup ring.

5. Slide the O-ring over the body of the fuel injectorand push it into the groove. Make sure the O-ringis against the cushion ring.

Middle Groove

6. Locate the middle groove seal.

7. Lightly lubricate the seal with clean engine oil.

8. Slide the middle seal over the fuel injector bodyand push into middle groove. Make sure themiddle fuel injector seal is against the groove.

Lower Groove

9. Locate the lower groove seal.

10. Lightly lubricate the lower O-ring seal with cleanengine oil.

11. Slide the lower O-ring seal over the fuel injectorbody and into the lower groove. Make sure thelower O-ring seal is against the groove.

12. Apply a light coat of grease to a new coppergasket. Place the gasket over the fuel injector tip.

13. Place fuel injector back into the holder rack forprotection from damage and dirt.




Cylinder Head Installation

NOTE: Valve lifters cannot be replaced or removedwhen the cylinder head is bolted onto the crankcase.Complete any required work to the valve lifters beforeinstalling the cylinder head.

Figure 169 Installing the Cylinder Head Onto theCrankcase

1. Crankcase2. Lifting Bracket3. Cylinder Head4. Dowel Sleeve5. Piston

1. If removed, install the two dowel sleeves (one atthe front and one at the rear of crankcase).

2. Place a new cylinder head gasket with the "UP"stamp facing towards the cylinder head. Do notapply sealant to the head gasket surfaces.

3. Install the cylinder head lifting bracket in thecenter of the cylinder head. Tighten the bracketmounting bolts.

CAUTION: To avoid engine damage, DONOT slide or drop the cylinder head on thecylinder head gasket. Either action coulddamage the gasket and dowel sleeves andmay result in a loss of compression or fluidleakage.

NOTE: When installing the cylinder head, align thedowel sleeves on both sides of the crankcase with themounting holes in the cylinder head.

4. Attach a lifting hook to the lifting bracket. Raisethe cylinder head and install it on the crankcase.

CAUTION: To avoid engine damage, DO NOTuse anti-seize compounds, grease, or anyother lubricant except engine oil. Otherlubricants have an adverse effect on torquevalues.

Do not install painted cylinder head bolts ina position under the valve cover. Paint chipsmay contaminate the engine oil.

Figure 170 Lubricating the Cylinder HeadMounting Bolts

1. Cylinder Head Mounting Bolts (18)2. Oil Can

5. Lightly lubricate all cylinder head mounting bolts(the threads and under the flange head) with cleanengine oil.

6. Install the cylinder head mounting bolts. Tightenthe mounting bolts in the special tighteningsequences and to the special torque values.




Install Fuel Injector

Figure 171 Installing the Shoulder Bolt

1. Shoulder Bolt2. Cylinder Head

1. Install the shoulder bolt and tighten it to the specialtorque value.

2. Lubricate the fuel injector O-rings. Insert the fuelinjector in the cylinder head bore.

3. Do not strike the top of the fuel injector to seat it.Use one of the following methods to seat the fuelinjector in the bore.

Figure 172 Open End Wrench Method

1. Hold Down Clamp2. Wrench3. Fuel Injector

Method One: Place the hold down clamp over theshoulder bolt. Use a 16 mm (5/8 in) open end wrenchon the lower edge of the hold down clamp to seat thefuel injector.

Figure 173 Installation Tool Method

1. Installation Tool2. Fuel Injector3. Hold Down Clamp

Method Two: Place a fuel injector installation toolonto the fuel injector. Slide the forks between the holddown clamp and the fuel injector head and rest the lipof the tool on the cylinder head. Turn the bolt on theinstallation tool to seat the fuel injector.




Figure 174 Installing the Fuel Injector HoldDown Clamp Mounting Bolt

1. Hold Down Clamp2. Fuel Injector3. Mounting Bolt

4. Install the mounting bolt for the hold down clamp.Tighten the bolt to the special torque value.

Install Oil Director Spout

Figure 175 Installing the Oil Director Spout

1. Hold Down Clamp2. Oil Director Spout3. Allen Head Bolt4. Fuel Injector

Install the oil director spout and secure it with an Allenhead bolt. Tighten the bolt to the special torque value.

Install Push Rods

NOTE: Clean push rods so the copper color ball endof the push rod can be identified.

Figure 176 Installing the Push Rods

1. Push Rod

Insert the push rods into their respective positions withthe copper color ball end up.




Install Valve Lever

CAUTION: To prevent engine damage, makesure the copper end of the push rods areup before proceeding. Then insert the otherend into the hydraulic roller lifter seats beforeinstalling the valve lever assemblies.

1. Rotate the crankshaft until the vibration dampernotch is 15 from vertical (1 o’clock positionwhen viewed from the front of the engine). Thispositions all pistons below TDC so the valvescannot contact the pistons when tightening thevalve lever assemblies.

Figure 177 Installing the Valve Lever Assembly

1. Push Rod Assembly2. Valve Lever Assembly3. Valve Lever Mounting Bolt

2. Lubricate the valve lever assemblies and boltswith clean engine oil.

3. Place the valve lever assemblies in their originallocations over the cylinder head mounting pads.Install retaining bolts finger tight.

4. Tighten the valve lever mounting bolts to thespecial torque value.

Install Glow Plug

Figure 178 Installing the Glow Plugs

1. Glow Plug2. Torque Wrench

Apply Never-Seez® to the threads of the glow plugs.Install the glow plugs into the cylinder head. Tightenthe glow plugs to the special torque value.

Connecting Under Valve Cover Harness

Figure 179 Installing the Valve Cover Gasket

1. Gasket With UVC Harness2. Fuel Injector Solenoid Harness Connectors3. Glow Plug Leads

1. Position the valve cover gasket with the UVCharness onto the cylinder head.

2. Connect the electrical leads to the glow plugs bypressing the connector onto the glow plugs.




Figure 180 Connecting the Connector to theFuel Injector Solenoid

1. Connector2. Gasket Surface

3. Connect the fuel injector electrical connector byinserting the connector into the socket. Push theconnector up and secure it with the metal wire bail.

4. Make sure all UVC wiring is free and clear of anymoving parts and free of possible entrapment bythe valve cover.

Installing Valve Covers

Figure 181 Installing the Left Valve Cover

1. Mounting Bolt (10)2. Valve Cover

Figure 182 Installing the Right Valve Cover

1. Mounting Bolt (4)2. Mounting Studs Bolt (6)3. Valve Cover

1. Place the valve cover onto the gasket. Be carefulto avoid pinching any UVC wires.

2. Install the mounting bolts finger tight. Make surethat the stud bolts on the right valve cover areinstalled in the correct locations.




Figure 183 Valve Cover Torque Sequence

3. Tighten the mounting bolts in the specifiedsequence and to the special torque value.

Figure 184 Installing the Oil Filler Standpipe

4. On the right valve cover, install the oil fillerstandpipe.

5. Connect the wiring harness connector to the UVCgasket.

6. After the valve cover is installed, refer to theappropriate procedures about installing the glowplug relay, turbocharger air inlet elbow, road drafttube, and ECM.

Crankcase BreatherRemoval

Figure 185 Removing the Crankcase Breather

1. Mounting Screws2. Crankcase Breather Assembly3. Left Valve Cover

1. Loosen the hose clamps that secure the road drafttube to the crankcase breather. Remove roaddraft tube from crankcase breather.

2. Remove the two screws that secure the crankcasebreather to the valve cover. Remove thecrankcase breather.

Cleaning

Clean the breather element in solvent. Dry thebreather element with filtered compressed air.




Installation

Figure 186 Installing the Crankcase Breather

1. Mounting Screws2. Large O-Ring Seals3. Crankcase Breather4. Left Valve Cover

CAUTION: To avoid damage to the engine BESURE the large O-ring seals are located onthe valve cover and the small O-ring seals areunder the mounting screw head. Failure todo so can result in the O-rings falling into thecylinder head causing damage to the engine.

1. Install the large O-rings onto the crankcasebreather and the small O-rings onto the mountingscrews.

2. Insert the mounting screws into the crankcasebreather.

3. Align the crankcase breather assembly with thetwo mounting holes on left valve cover. Tightenthe screws to the special torque value.

4. Install the road draft tube to the crankcasebreather. Tighten the hose clamps that securethe tube to the crankcase breather.

Assemble the following after the cylinder head isinstalled. Refer to the appropriate section for correctinstallation procedures.

• Fuel lines and filter assembly

• High pressure hydraulic lines

• Engine harness connections

• ECM




SPECIFICATIONS

Table 10 Cylinder Head

Exhaust Valves

Stem Diameter 7.9210-7.9388 mm (0.31185-0.31255 in)

Stem To Guide Clearance (Max. Allowable BeforeReplacement) 0.140 mm (0.0055 in)

Face To Stem Runout (T.I.R. Max.) 0.05 mm (0.002 in)

Valve Face Angle 37.5

Valve Face Margin (Min.) 1.37 mm (0.054 in)

Intake Valves




Valve Face Angle 30


Cylinder Heads

Inside Diameter Of Valve Guide 7.978-8.004 mm (0.3141-0.3151 in)

Valve Guide Taper (Max.) 0.10 mm (0.004 in)

Valve Seat Width (intake and exhaust) 1.65-2.41 mm (0.065-0.095 in)

Valve Seat Angle (intake) 30

Valve Seat Angle (exhaust) 37.5

Valve Seat Run Out (T.I.R. Max.) 0.05 mm (0.002 in)

Gasket Surface Flatness 0.025 mm in 0.5 mm (0.001 in. in 2 inches) 0.10 mm (0.004 in) overall

Gasket Surface Finish (Micro Inches) 63-125

Deck To Deck Dimension (Head ThicknessOverall) 129.41-129.67 mm (5.095-5.105 in)

Valve Head Recession Relative To Deck (Head Gasket) Surface On Cylinder Head

Intake 1.17-1.47 mm (0.046-0.058 in)

Exhaust 1.32-1.63 mm (0.052-0.064 in)

Valve Spring

Free Length 52.70 ± 3.8 mm (2.075 ± 0.150 in)

Test Length 34.34 mm (1.352 in)

Load at Test Length 102-113 kg (225-249 lbf)

Push Rod Runout/Straightness (Max. T.I.R.) 0.518 mm (0.02 in)




Special Torque

Table 11 Cylinder Head Special Torques

Crankcase Breather Screws 2 N·m (18 lbf·in)

Initial: 54 N·m (40 lbf·ft)

Second: 95 N·m (70 lbf·ft)Cylinder Head Mounting Bolts (special torquesequences)

Final: 129 N·m (95 lbf·ft)

Fuel Injector Hold Down Clamp Mounting Bolt 14 N·m (120 lbf·in)

Fuel Injector Shoulder Bolt 14 N·m (120 lbf·in)

Fuel Rail End Plugs 16.3 N·m (12 lbf·ft)

Glow Plugs 19 N·m (14 lbf·ft)

ICP Sensor 29 ± 2 N·m (21.5 ± 1.5 lbf·ft)

Oil Deflector Mounting Bolt 12 N·m (106 lbf·in)

Oil Fill Deflector 11–16 N·m (8–12 lbf-ft)

Oil Rail Drain Plugs 6.8 ± 1 N·m (60 ± 10 lbf·in)

Oil Rail End Plugs 81 N·m (60 lbf·ft)

Oil Rail Plugs 29 ± 2 N·m (21.5 ± 1.5 lbf·ft)

Valve Cover Bolts (special torque sequence) 11 N·m (8 lbf·ft)

Valve Lever Mounting Bolt 27 N·m (20 lbf·ft)

Figure 187 Valve Cover Bolt Special Torque Sequence

1. Start all bolts by hand and finger-tighten.




2. Torque bolts to the special torque value in thesequence shown.

Figure 188 Cylinder Head Mounting Bolt Special Torque Sequence

1. Tighten to 54 N·m (40 lbf·ft) in numberedsequence.


3. Tighten to 129 N·m (95 lbf·ft) in line sequence.

4. Tighten to 129 N·m (95 lbf·ft) again in linesequence.





Table 12 Cylinder Head Special Service Tools

OEM1004 Outside Micrometer (5–6 inch)

OEM1014 Dial Caliper

OEM1023 Small Hole Gauge Set

OEM1272 Defect Detection Kit (Dye Penetrant)


OEM6343 Cleaning Brush

OEM6459 Surface Height Gauge Tool

ZTSE1631A Eccentric Valve Seat Grinder

ZTSE1846 Valve Spring Compressor

ZTSE1879 Slide Hammer Puller Kit

ZTSE2241 Valve and Clutch Spring Tester


ZTSE4297 Cylinder Head Lifting Bracket


ZTSE4299 Fuel Injector Holder Rack

ZTSE4300 Fuel Injector Removal Tool

ZTSE4301 Fuel Injector Tip Cleaning Brush

ZTSE4302A Fuel Injector Sleeve Removal Tool

ZTSE4303 Fuel Injector Sleeve (Adapter) Replacer

ZTSE4304 Fuel Injector Sleeve Cleaning Brush Set

ZTSE43042 Injector Sleeve Bottom Brush

ZTSE4308 Cylinder Head Pressure Test Plate

ZTSE4320 Oil and Fuel Gallery Brush Cleaning Set (Consists of 4 brushes)

ZTSE4353 Fuel Injector Installation Tool


ZTSE43862 Hand Tap (Bottoming M12 X 1.75)

ZTSE43021A Injector Sleeve Tap



OIL PAN, VIBRATION DAMPER, OIL PUMP WATER PUMP, ANDFRONT COVER

123

Table of Contents

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126Oil Pan.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126Oil Pick-Up Tube.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126Vibration Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127Vibration Damper Wear Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128Front Oil Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128Oil Pump.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128Water Pump.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130

Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130Oil Pan.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130Vibration Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130Oil Pump.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131Water Pump.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131

Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131Oil Pick-Up Tube.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131Vibration Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131Oil Pump.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131Water Pump.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133Vibration Damper Wear Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133Front Cover and Water Pump.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134Oil Pump.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135Front Oil Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137Vibration Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138Oil Pick-Up Tube.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138Oil Pan.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140

Special Torque.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140




124 OIL PAN, VIBRATION DAMPER, OIL PUMP WATER PUMP, ANDFRONT COVER




125

Figure 189 Oil Pump and Pick-Up Assembly

1. Vibration Damper2. Front Seal3. Oil Pump Housing4. Oil Pump Gerotor Assembly5. Outer Oil Pump Gerotor6. Inner Oil Pump Gerotor7. Oil Pump Housing Gasket

8. Front Cover9. Front Cover Gasket (2)10. Oil Pick-Up Tube Bracket11. Oil Pan12. Oil Pick-Up Tube Gasket13. Oil Pick-Up Tube




RemovalOil Pan

NOTE: BE SURE oil pan has been drained beforeremoving.

Figure 190 Removing Oil Pan Mounting Bolts

1. Remove the oil filter.

2. Remove the oil pan mounting bolts.

Figure 191 Cutting the RTV Sealant on the OilPan

1. Hammer2. RTV Sealant Cutting Tool3. Oil Pan

3. Use a cutting tool to cut through the RTV sealanton both oil pan rails.

Figure 192 Removing the Oil Pan From theCrankcase

4. Pry the oil pan down on one side to break the RTVsealant at the front cover and rear plate. Roll theoil pan off to the side to free it from the engine.

Oil Pick-Up Tube

Figure 193 Removing the Oil Pick-Up Tube

1. Mounting Bolt (2)2. Oil Pick-Up Tube3. Support Bracket4. Bracket Nut

Remove the two mounting bolts and the bracket nutfrom the oil pick-up tube. Remove the oil pick-up tube.




127

Vibration Damper

Figure 194 Checking the Vibration DamperRunout

1. Paint Removal Areas (4 locations at 90 intervals)2. Dial Indicator

1. Before removing the vibration damper, check thevibration damper runout as follows:

NOTE: Pry only in one direction to eliminate anypossible error induced by crankshaft end play.

a. Remove any paint from the face of thevibration damper at four points 90 apart.

b. Attach a magnetic base dial indicator to thefront of the crankcase or oil pan. Position theindicator point on the unpainted surface.

c. Pry the crankshaft forward and zero theindicator. The zero point is now the baseline.

d. Turn the crankshaft 90 and pry the crankshaftforward. Record the reading.

e. Repeat Step d at each unpainted surface.If the runout exceeds specifications, replacevibration damper.

Figure 195 Removing the Vibration DamperMounting Bolt

1. Vibration Damper2. Washer3. Mounting Bolt

2. Remove the vibration damper mounting bolt.Remove the washer and loosely install themounting bolt so the puller does not damage thebolt threads during removal.

Figure 196 Removing the Vibration DamperAssembly

1. Vibration Damper2. Puller3. Forcing Screw4. Removal Bolts (3)

3. Mount the vibration damper removal tool to thedamper with the three bolts that are provided.

4. Insert the forcing screw and turn it in against themounting bolt. The vibration damper will be pulledoff the crankshaft. Remove the mounting bolt andthe damper.




Vibration Damper Wear Sleeve

NOTE: Whenever the vibration damper is removed,the vibration damper wear sleeve must be replaced.Make sure the vibration damper has been cleanedand inspected before proceeding with the wear sleeveremoval.

Figure 197 Removing the Vibration DamperWear Sleeve

1. Vibration Damper2. Wear Sleeve Removal Tool3. Wear Sleeve

1. Install the wear sleeve removal tool on thevibration damper.

2. Turn the forcing screw to remove the wear sleeve.

Front Oil Seal

Figure 198 Removing the Front Oil Seal

1. Oil Pump Housing2. Front Oil Seal3. Oil Seal Removal Tool

Use the oil seal removal tool to pry the front oil sealfrom the oil pump housing.

Oil Pump

Figure 199 Removing Oil Pump HousingMounting Bolts

1. Retainer Bolts (4)2. Oil Pump Housing

1. Remove the four mounting bolts for the oil pumphousing.




129

Figure 200 Removing Oil Pump Housing andOuter Gerotor Gear

1. Oil Pump Housing2. Seal Ring3. Outer Gerotor

2. Remove the oil pump housing with seal ring andthe outer gerotor. Discard the seal ring.

NOTE: The crankshaft woodruff key can remain inplace when removing the inner gerotor.

Figure 201 Removing Inner Gerotor FromCrankshaft

1. Inner Gerotor

3. Remove inner gerotor gear by sliding it offcrankshaft.

Water Pump

1. Remove the coolant filter from the water pumphousing.

2. Remove the mounting bolts that secure the waterpump to the front cover.

Figure 202 Water Pump Mounting Bolts

1. 30 mm (1–1/4 in)2. 60 mm (2–1/2 in)3. 100 mm (4 in)

3. Remove and discard the water pump gasket.




Front Cover

Figure 203 Front Cover and Mounting Bolts

1. Front Cover2. Mounting Bolts

NOTE: Refer to Water Pump Removal if removing thewater pump.

Figure 204 Water Pump and Mounting Bolts

1. Remove the four front cover mounting bolts andfour water pump mounting bolts that secure thefront cover to the crankcase.

Figure 205 Removing the Front Cover From theCrankcase

1. Front Cover2. Front Cover Gaskets

2. Remove the front cover from the crankcase.

3. Remove and discard the gaskets from the frontcover.

CleaningOil Pan

Thoroughly clean the RTV sealant from the oil pan andcrankcase mating surfaces and from the bolt holes inthe crankcase and oil pan.

Vibration Damper

CAUTION: Do not immerse the vibrationdamper in a petroleum based solvent.Damage to the rubber damping element mayresult.

Clean the vibration damper with soap and water. Dryit with filtered compressed air.




131

Oil Pump

Wash all parts thoroughly in a suitable solvent. Drythe parts with filtered compressed air.

Water Pump

Wash the water pump thoroughly in a suitable cleaningsolvent. Dry the pump with filtered compressed air.

Front Cover

Clean the RTV sealant and gasket material from thefront cover, crankcase and mating surfaces.

InspectionOil Pick-Up Tube

Inspect the pick-up tube for cracks at the seams andbrazed connections. Replace the tube if required.

Vibration Damper

Figure 206 Vibration Damper Components

1. Keyway2. Inner Member3. Rubber Member4. Outer Member5. Timing Mark

Use a protractor to measure the angle between thetiming mark and the center of the key way. If the angleis not 164 , replace the vibration damper.

Oil Pump

1. Inspect the gerotors and housing for nicks, burrsor scoring. Replace any damaged components.

CAUTION: When placing the inner and outergerotors into the oil pump housing, makesure the word "damper" is facing the oilpump housing. Failure to do so will result inengine damage.

NOTE: The inner and outer gerotors are a matchedset. They cannot be replaced separately.

2. Place the inner and outer gerotors in the oil pumphousing.

Figure 207 Inspecting Gerotors For Wear

1. Outer Gerotor2. Oil Pump Housing3. Feeler Gauge

3. To check for wear, use a feeler gauge to measurethe radial clearance between the outer gerotorand the pump housing.




Figure 208 Checking the Oil Pump EndClearance

1. Oil Pump Housing2. Gerotors3. Feeler Gauge4. Straightedge

4. Check the oil pump end clearance as follows:

a. With the O-ring removed and the gerotorsin place in the oil pump housing, place astraightedge across the housing.

b. Insert a feeler gauge under the straightedgeat the inner and outer gerotors and comparethe end clearance with the specification.

5. If the measurements are not within thespecifications, replace the components asrequired.

Water Pump

Inspect the water pump for cracks and damage.Replace the pump if necessary.

Front Cover

1. Inspect the front cover for cracks and damage.

2. Place the mounting surface of the front cover ona smooth flat surface and check for warp.

3. Replace the front cover if cracked, damaged orwarped.




133

InstallationVibration Damper Wear Sleeve

Figure 209 Installing the Vibration Damper WearSleeve

1. Wear Sleeve Installation Tool2. Wear Sleeve3. Loctite® #2714. Vibration Damper5. Press

NOTE: Make sure the vibration damper is clean andfree of oil before installing the wear sleeve.

1. Apply Loctite® #271 around the inside diameter ofthe wear sleeve. Place the wear sleeve onto thewear sleeve installation tool.

2. Position the wear sleeve in the installation tool sothe outer chamfer is facing toward the tool.

3. Place the installation tool on a press table.Position the vibration damper over the wearsleeve installation tool and lower the damper ontothe wear sleeve installation tool.

4. Use a press to apply pressure to the inner memberof the vibration damper until the installation toolbottoms out or seats.




Front Cover and Water Pump

CAUTION: Failure to properly install thefront cover may result in engine damage.To properly install the front cover, the waterpump must be installed before tighteningthe front cover mounting bolts. Four of thewater pump mounting bolts also secure thefront cover.

Figure 210 Installing the Gaskets and ApplyingRTV to the Front Cover

1. New Gaskets2. Sealant Locations3. Front Cover

1. Position two new gaskets on the front cover. ApplyRTV sealant in the remaining grooves of the frontcover and around the front cover dowel pins.

Figure 211 Installing the Front Cover to theCrankcase

1. Front Cover2. Front Cover Mounting Bolts

2. Fasten the front cover to the crankcase. Install thefront cover mounting bolts finger tight.

3. Place a new gasket in the water pump gasketgroove.

CAUTION: Failure to properly mount thewater pump and obtain a correct seal mayresult in engine damage. To properly mountthe water pump and obtain a correct seal,install the water pump mounting bolts intotheir proper locations.




135

Figure 212 Water Pump Mounting Bolts

1. 30 mm (1–1/4 in)2. 60 mm (2–1/2 in)3. 100 mm (4 in)

4. Install the water pump on the front cover. Installthe water pump mounting bolts and tighten thebolts to the standard torque values.

5. Tighten the front cover mounting bolts to thestandard torque value.

Figure 213 Installing Coolant Filter

1. Front Cover2. Water Pump3. Coolant Filter4. Coolant Filter Shutoff Valve (ON Position)5. Coolant Filter Shutoff Valve (OFF Position)

6. Apply a thin coat of new coolant to the coolantfilter gasket. Thread the coolant filter onto the filterheader.

7. Tighten the filter until the gasket touches theheader. Tighten it by hand an additional 1/2 turn.

8. Open the coolant filter shutoff valve on the waterpump.

Oil Pump

CAUTION: When installing the inner andouter gerotor, make sure the word "damper"is facing towards the front of the engine.Failure to do so will result in engine damage.

Figure 214 Installing the Inner Gerotor

1. Inner Gerotor

1. Install the inner gerotor over the crankshaftnose with the word “damper” facing the oil pumphousing.




Figure 215 Installing Outer Gerotor and SquareCut Ring

1. Oil Pump Housing2. Outer Gerotor3. Seal Ring

2. Lubricate the outer gerotor with clean engine oil.Install the gerotor in the oil pump housing with theword “damper” facing the oil pump housing.

3. Pack cavities between and around the gerotor withan all purpose assembly grease to insure properpriming at engine startup.

4. Install square cut seal ring in the oil pump housinggroove.

Figure 216 Installing the Oil Pump Housing

5. Align dowel pins and install oil pump housing withseal ring and large gerotor gear onto crankshaft.

6. Install four oil pump housing mounting bolts.Tighten bolts to standard torque value.




137

Front Oil Seal

Figure 217 Installing Front Oil Seal

1. Damper/Crankshaft Oil Seal Installation Tool2. Oil Seal3. Oil Pump Housing4. Crankshaft5. Forcing Screw

1. Place front oil seal onto the installation tool. Applya thin coat of Aviation Permatex No. 3 to theoutside diameter of the seal.

Figure 218 Seating the Front Oil Seal

1. Forcing Nut2. Installation Tool3. Oil Seal

2. Position the installation tool over the forcing screwand tighten the forcing nut. Make sure the toolbottoms out against the housing so the oil seal isfully seated in the housing.




Vibration Damper

1. Apply RTV sealant to the vibration damperkeyway. This prevents oil seepage throughdamper keyway. Align the keyway in the damperwith the key on the crankshaft and install thedamper.

Figure 219 Installing the Vibration DamperInstallation Tool

1. Installer Plate2. Vibration Damper3. Forcing Nut

NOTE: ZTSE4310 is a combination tool. One side isused to install the front oil seal while the other side isused to install the vibration damper.

2. Assemble the puller screw, installer plate, thrustwasher and nut.

3. Turn nut to draw the vibration damper onto thecrankshaft.

4. Remove the installation tool.

Figure 220 Securing the Vibration Damper tothe Crankshaft

1. Vibration Damper

5. Apply RTV sealant to the washer and undersideof the bolt head. Install the washer and mountingbolt. Tighten the bolt to the special torque value.

Oil Pick-Up Tube

Figure 221 Installing the Oil Pick-Up TubeO-Ring

1. Install the O-ring on the oil pick-up tube mountingflange. If necessary, use a small amount of RTVsealant to hold the O-ring in place.




139

Figure 222 Installing the Oil Pick-Up Tube

1. Mounting Bolt (2)2. Oil Pick-Up Tube3. Support Bracket4. Bracket Nut

2. Install the oil pick-up tube and mounting bolts.Tighten the bolts finger tight.

3. Adjust the bracket at the main bearing cap studand install the nut. Tighten the mounting boltsto the standard torque value after alignment.Tighten the bracket nut at the main bearing capstud last.

Oil Pan

CAUTION: Do not apply excessive amountsof RTV sealant. Some could end up in the oilpick-up screen and restrict oil flow. Such arestriction may result in engine damage. Toavoid damaging the crankcase, make sure nosealant gets in the bolt holes.

1. Wipe excess oil and foreign matter from all oil pansealing surfaces. Use brake cleaner to thoroughlydegrease all sealing surfaces before applyingRTV sealant.

Figure 223 Apply RTV Sealant to the CrankcaseRails

2. Apply RTV sealant to the entire crankcasemounting surface to prevent leaks. Apply moreat the front and rear mating surfaces. Apply thesealant between and around the bolt holes.

3. Install guide studs at two places on the crankcaseto ensure proper oil pan alignment. Install the oilpan.

Figure 224 Oil Pan Bolt Hole Locations

4. Install mounting bolts finger tight. Remove theguide studs. Replace them with mounting bolts.Tighten all mounting bolts to the standard torquevalue.




SPECIFICATIONS

Table 13 Vibration Damper, Lubricating Oil Pump, Oil Pan, Oil Pick-Up Tube and Front Cover

Lubricating Oil Pump

Type Gerotor

End Clearance - inner and outer rotor to housing 0.02-0.08 mm (0.001-0.003 in)

Radial clearance between outer rotor housing 0.71-0.81 mm (0.028-0.032 in)

Engine Lube Oil Pressure at Operating Temperature

At low idle speed (700 rpm) minimum 69 kPa (10 psi)

At high idle speed 241-483 kPa (35-70 psi)

Engine Oil Capacity

Without filter 17 liters (18 quarts)

With filter 18.5 liters (19.5 quarts)

Vibration Damper

Vibration damper mounting area runout (maximum) 0.13 mm (0.005 in)

Special Torque

Table 14 Vibration Damper, Lubricating Oil Pump, Oil Pan, Oil Pick-Up Tube and Front Cover SpecialTorques


Oil Pan Mounting Bolts 34 N·m (25 lbf·ft)

Oil Pick-Up Tube Flange Mounting Bolts 24 N·m (18 lbf·ft)


Vibration Damper Mounting Bolt 287 N·m (212 lbf·ft)

Water Pump Pulley Mounting Screw 41 ± 7 N·m (30 ± 5 lbf·ft)




141


Table 15 Vibration Damper, Lubricating Oil Pump, Oil Pan, Oil Pick-Up Tube and Front Cover SpecialService Tools

OEM1028 Magnetic Base Dial Indicator


ZTSE229569 Vibration Damper Removal Tool

ZTSE4300 Fuel Injector/Front Oil Seal Removal Tool

ZTSE4310 Front Oil Seal/Vibration Damper Installation Tool

ZTSE4314 Vibration Damper Wear Ring Removal Tool

ZTSE4315 Vibration Damper Wear Ring Installation Tool

ZTSE4385 Oil Pan Removal Tool



VALVE TRAIN: PUSH RODS, HYDRAULIC VALVE LIFTERS ANDCAMSHAFT

143

Table of Contents

Push Rods and Hydraulic Valve Lifters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147Cleaning.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148Leak Down Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149

Camshaft and Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150Check Gear Backlash and Camshaft End Play. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151Cleaning .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152Assembling Cam Gear to Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153Installation of Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155

Special Torque.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155




144 VALVE TRAIN: PUSH RODS, HYDRAULIC VALVE LIFTERS ANDCAMSHAFT




145

Figure 225 Valve Train Components

1. Camshaft Gear2. Thrust Plate3. Camshaft4. Hydraulic Valve Lifter

5. Valve Push Rod6. Copper Colored End7. Valve Lever8. Valve




Push Rods and Hydraulic ValveLiftersOperation

NOTE: As a general rule, hydraulic valve lifters shouldnot require any service if they are operating quietlyand functioning satisfactorily.

Figure 226 Valve Lifter Components

1. Lifter Body with Roller2. Spring3. Plunger4. Plunger Body5. Metering Valve6. Push Rod Seat7. Retainer

Lube oil from the oil gallery is supplied to the liftersthrough a hole in the side of the lifter body that indexeswith a groove and hole in the lifter plunger. Oil is thenmetered past the oil metering valve, up through thepush rods and onto the valve levers.

When the lifter begins to roll up the cam lobe, themetering valve is held against its seat in the plungerbody by the spring. This action traps the oil in the baseof the lifter body below the plunger. The plunger bodyand lifter body then rise as a unit, pushing the pushrod up in order to open the valve. The spring forceexerted on the plunger through the valve lever andpush rod causes a slight amount of leakage betweenthe plunger and lifter body.

"Leak down" is the term used to describe this leakage.Leak down allows a slow escape of trapped oil in thebase of the lifter body. As the lifter rides down theother side of the cam lobe and reaches the base circleor "valve closed" position, the plunger spring quicklymoves the plunger back up to its original position. Thismovement causes the check valve to open against thecheck valve spring and allows oil to be replenishedfrom the oil gallery. This restores the lifter to zero lash.




147

Removal

CAUTION: To avoid engine damage, thevalve lifters and push rods must be kept inorder so they can be installed in their originalpositions.

Figure 227 Removing the Push Rods

1. Push Rod

1. Remove the push rods from the crankcase.

Figure 228 Removing the Valve Lifter Guide

1. Valve Lifter Guide2. Valve Lifter

2. Remove the retaining bolt from the center of eachvalve lifter guide. Remove the valve lifter guidesfrom the crankcase.

Figure 229 Removing the Valve Lifter

1. Valve Lifter

3. Remove the hydraulic valve lifters from thecrankcase. Note the orientation of the lifterswithin the bore so they can be installed later intheir original positions.

Disassembly

Figure 230 Disassembling the Valve Lifter

1. Lifter Body with Roller2. Plunger Spring3. Plunger4. Plunger Body5. Metering Valve6. Push Rod Seat7. Retainer

1. Use a small screwdriver to remove the push rodseat retainer.

2. Remove the push rod seat and metering valve.

3. Remove the plunger, plunger body, and plungerspring.




Cleaning

Clean the push rods and all the parts of the hydraulicvalve lifters with a suitable cleaning solvent. Dry theparts with filtered compressed air.

Inspection

1. Inspect all disassembled parts for nicks, burrs orscoring. If signs of damage are evident, replacethe entire hydraulic valve lifter.

2. Inspect each push rod for wear and deposits thatmay restrict the flow of oil into the valve leverassemblies. Replace the push rods as required.

Figure 231 Checking the Push Rod Flatness

3. Check all cleaned push rods by rolling themon a flat surface. If they are not straight or arequestionable, refer to the specifications for pushrod runout. If the specifications are exceeded,replace the push rod.

CAUTION: If the roller fails any one of thefollowing inspection criteria, the camshaftlobes must be inspected for damage. Failureto do so may result in damage to the engine.

4. While pushing on the valve lifter roller in a normaldirection of load, check for free rotation of theroller. Check the axial movement between the pinand roller.

NOTE: the valve lifter roller is crowned by design.Therefore, a normal wear pattern will typically becentered on the roller contact surface.

5. Inspect the roller for pitting or roughness.

Assembly

CAUTION: To avoid engine damage afterassembly, perform a leak down test toensure that leakage past the plunger andlifter body is correct. This assures that thecheck valve is functioning properly.

Figure 232 Assembling the Valve Lifter

1. Lifter Body with Roller2. Plunger Spring3. Plunger4. Plunger Body5. Metering Valve6. Push Rod Seat7. Retainer

1. Coat all hydraulic valve lifter parts with cleanengine oil.

2. Install the plunger spring and plunger into theplunger body, then into the lifter body.

3. Install the metering valve and push rod seat intothe valve lifter body. Secure the components witha retaining ring.




149

Leak Down Test

Figure 233 Valve Lifter Tester

This test is used to determine whether leakage pastthe plunger and lifter body is correct and whether thecheck valve is functioning properly.

NOTE: Use a test fluid specified by the toolmanufacturer. Make sure that the fluid is at roomtemperature.

Use a hydraulic valve lifter tester to check the leakdown rate. Follow the instructions that come with thetesting unit.

The leak down rate is how many seconds it takes forthe plunger to move a specified portion of the distanceit will travel while under a 23 kg (50 lb) load. Refer tothe specifications.

Installation

Figure 234 Installing the Valve Lifters Into theCrankcase

1. Hydraulic Valve Lifters2. Piston

1. Lubricate the valve lifters with clean engineoil. Install the valve lifters into their respectivebores within the crankcase. Maintain the originaldirection of rotation.

Figure 235 Installing the Valve Lifter Guide

1. Valve Lifter Guide2. Valve Lifter

2. Install the valve lifter guides over the hydraulicvalve lifters. Secure each guide to the crankcasewith a retaining bolt and tighten the bolts to thestandard torque value.




CAUTION: To ensure the compatibility of themetallic mating surfaces of the valve lever,push rod, and valve lifter, the copper coloredend must face up when installed. Be awarethat the two rounded ends of each push rodare made of different materials.

Figure 236 Installing the Push Rods

1. Push Rod

3. Make sure the copper colored ball end is facingup. Insert the push rods into their respectivepositions.

Camshaft and GearCheck Gear Backlash and Camshaft End Play

Figure 237 Checking theCamshaft-to-Crankshaft Gear Backlash

1. Dial Indicator2. Camshaft Gear

1. Before removing the camshaft, check and recordthe camshaft gear-to-crankshaft gear backlash asfollows:

a. Mount a dial indicator on the front of theengine.

b. Position the dial indicator tip on a gear toothand remove all lash.

c. Place a small pry bar between the camshaftand crankcase. Lightly pry the camshaftforward.

d. Zero the dial indicator while lightly prying thecamshaft forward.

e. Rotate the gear by hand while lightly pryingthe camshaft forward. Record the amount ofbacklash.




151

Figure 238 Checking the Camshaft End Play

1. Dial Indicator

2. Reposition the dial indicator and check thecamshaft end play as follows:

a. Push the camshaft toward rear of engine.

b. Zero the dial indicator.

c. Place a small pry bar between the camshaftgear and crankcase. Lightly pry the camshaftforward. Compare the dial indicator readingwith the specifications.

d. If the end play exceeds the specifications,replace the camshaft.

e. Remove the dial indicator.

Removal

NOTE: Check the valve lifters for wear prior to anycamshaft replacement. Remove the valve lifters andpush rods before camshaft removal.

NOTE: If the engine is mounted on a turn over stand,rotate the engine so that the front of engine is facingup to a vertical position. This position allows for easyremoval of the camshaft assembly.

Figure 239 Removing the Cam Gear Thrust PlateMounting Bolts

1. Cam Gear Thrust Plate Bolts2. Camshaft Gear

1. Remove the two cam gear thrust plate mountingbolts.




Figure 240 Removing the Camshaft Assembly

1. Camshaft Assembly

2. Remove the camshaft from the crankcase bylifting the assembly straight up.

3. Use a hydraulic press to remove the camshaftgear from the camshaft, if necessary.

Cleaning

Wash the camshaft in cleaning solvent with a softbrush. Dry it with filtered compressed air.

Inspection

NOTE: This engine uses hydraulic valve lifters withroller followers. Therefore, a lifter guide is neededto maintain proper roller-to-cam lobe orientation.Normal clearance between hydraulic valve lifter andguide allows slight tracking of the roller across thecam lobe.

The tracking of a hydraulic valve lifter roller isa normal characteristic as the roller acceleratesand decelerates during typical engine operation.Consequently, a typical wear pattern on the camlobes will exhibit tracks from side to side and willhave wide and narrow areas from the loading andunloading of the follower. The visual wear pattern(tracking) is normal. It does not require camshaftreplacement.

1. Inspect camshaft. If any lobes are scuffed, scoredor cracked, replace the camshaft.

2. Use a micrometer to measure camshaft journaldiameter. If the journals are worn beyondspecifications, replace camshaft.




153

Figure 241 Checking Camshaft Lobes

1. Camshaft2. Micrometer

3. Use a micrometer to check camshaft lobe wear.Measure across lobes (A-C and B-D). Subtractdimension B-D from dimension A-C. This is thecam lobe lift. Replace camshaft if cam lobe wearexceeds specifications.

4. Inspect the thrust plate for wear, cracks anddistortion. Use a micrometer to measure thrustplate thickness. Replace the thrust plate if it isdamaged or worn beyond the specification.

5. Inspect the camshaft drive gear for worn ordamaged teeth. Inspect the CMP sensor timingdisk attached to the front face of the cam gear. Ifeither of these components is worn or damaged,replace the gear and timing disk as an assembly.

Assembling Cam Gear to Camshaft

WARNING: To avoid serious personalinjury or possibly death, use welding glovesfor this procedure.

CAUTION: The replacement cam gear andtiming disk assembly have been accuratelytimed at the factory. Because accuratetiming upon reassembly cannot be assured,do not disassemble these components.Disassembly may consequently result inengine damage.

Figure 242 Assembling the Cam Gear Onto theCamshaft

1. Gear Teeth2. Timing Disk

1. Heat the cam gear and timing disk assembly in anoven to 260 C (500 F).

2. While the assembly is heating, position thecamshaft vertically near the oven. Clean the noseof the camshaft.

3. Install the thrust plate on its journal and place thecam gear key in its slot.




4. Wear welding gloves to remove the cam gearassembly from the oven. Quickly align thegear keyway with the key and position the gearassembly over the nose of the camshaft untilthe gear is seated against the retaining flangeshoulder.

5. Allow the assembly to cool before installing thecamshaft in the engine. Do not quench.

Installation of Camshaft

NOTE: If new parts are installed, make sure the gearbacklash and end play are within specifications.

1. Coat the camshaft lobes and bushing journalswith clean engine oil.

NOTE: Avoid nicking or scratching the camshaftbushings by the cam lobes.

Figure 243 Installing the Camshaft Assembly

1. Camshaft

2. Position the crankcase on engine the stand withthe front facing up. Carefully install the camshaftassembly.

Figure 244 Indexing the Cam Gear andCrankshaft

1. Cam Gear2. Crankshaft Gear3. Crankshaft Gear Timing Mark4. Cam Gear and Timing Disk Marks

3. Index the cam gear and crankshaft gear so timingmarks are aligned when the camshaft is in place.

Figure 245 Installing the Thrust Plate Bolts

1. Crankshaft2. Camshaft Gear3. Crankcase

4. Install two thrust plate mounting bolts. Tighten thebolts to the special torque value.




155

SPECIFICATIONS

Table 16 Valve Train

Camshaft

Bearing Journal Diameter (All Journals) 53.31-53.34 mm (2.099-2.100 in)

Bearing (Bushing) Inside Diameter 53.39-53.48 mm (2.102-2.105 in)

Journal/Bushing Running Clearance 0.051-0.165 mm (0.002-0.006 in)

Camshaft End Play 0.051-0.203 mm (0.002-0.008 in)

Timing Gear Backlash 0.140-0.2794 mm (0.0055-0.0110 in)

Maximum Permissible Cam Lobe Wear 0.51 mm (0.020 in)

Journal Surface Finish (microinches) 16 µin

Camshaft Thrust Plate Thickness 3.910-3.960 mm (0.154-0.156 in)

Camshaft Lobe Lift

Intake 6.44 mm (0.2535 in) max.

Exhaust 6.43 mm (0.2531 in) max.

Valve Timing No. 1 Cylinder (Top of Ramp)

Intake Open 17.2 BTDC

Closed 34.8 ABDC

Exhaust Open 51.2 BBDC

Closed 20.8 ATDC

Hydraulic Valve Lifters

Diameter 23.391-23.411 mm (0.9209-0.9217 in)

Bore Diameter In Crankcase 23.439-23.477 mm (0.9228-0.9243 in)

Clearance In Bore 0.027-0.086 mm (0.0011-0.0034 in)

Bleed Down Rate – Time required for plunger to move3.175 mm (0.125 in) under a 50 lb load using testfluid at room temperature

18-90 seconds

Special Torque

Table 17 Valve Train Special Torques

Cam Follower Guide Mounting Bolt 20 N·m (15 lbf·ft)





Table 18 Valve Train Special Service Tools

OEM1000 Micrometer


ZTSE1893 Hydraulic Valve Lifter Tester



CRANKCASE, CRANKSHAFT, CONNECTING RODS, AND PISTONS 157

Table of Contents

Flywheel and Flywheel Housing.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161Cleaning.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162Resurfacing (Manual Transmissions). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162Installation of Flywheel Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163Check Flywheel Housing Bore Concentricity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164Check Flywheel Housing Face Runout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164Check Flywheel Surface Runout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165Check Crankshaft Pilot Concentricity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165Installation of Flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165

Rear Oil Seal and Wear Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166

Rear Oil Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166Wear Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167

Rear Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169Cleaning.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169

Connecting Rods, Pistons and Piston Rings.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169Check Piston Protrusion.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169Checking Connecting Rod Side Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173Cleaning.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174Check Width of Top Compression Ring Groove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174Checking Side Clearance Of Oil Control Ring And Intermediate Compression Ring Groove.. .175Piston Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175Check Piston Ring End Clearance in Cylinder Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176Connecting Rods.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176Check Inside Diameter of Piston Pin Bushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177Check Connecting Rod Bearing Bore for Out-of-Round and Taper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177Check Connecting Rod for Bend or Twist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178Check Piston Pin Clearance.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178Bearing Fitting Procedure For Old Style Connecting Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179Assembly – Old Style Connecting Rod.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181Assembly – New Style Connecting Rod.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182Installation – Old Style Connecting Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184Installation – New Style Connecting Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188

Crankshaft and Main Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190



158 CRANKCASE, CRANKSHAFT, CONNECTING RODS, AND PISTONS

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190Cleaning.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192Check Crankshaft Journals for Out-of-Round and Taper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192Installation of Crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192Main Bearing Fitting Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193Installation of Main Bearing Caps.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194Check Crankshaft End Play. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195

Piston Cooling Jets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196

Crankcase Reconditioning.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197Cleaning.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197Inspect Short Circuit Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197Replace Crankcase Cup Plugs.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197Check Crankcase Surface for Flatness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198Check Cylinder Bore for Out-of-Round and Taper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198Deglazing.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199

Camshaft Bushings.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200Check for Wear and Proper Running Clearance.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203

Special Torque.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206





Figure 246 Crankcase, Flywheel Housing And Related Parts

1. Front Camshaft Bushing2. Camshaft Bushing (2nd – 5th)3. Crankcase4. Short Circuit Oil Plug5. Short Circuit O-Ring6. Short Circuit Spring7. Short Circuit Ball8. Seat, Ball9. Cup Plug (7)10. Dowel Sleeve (4)

11. Valve Lifter Guide Retainer12. Valve Lifter Guide Bolt13. RTV, Liquid Gasket14. Rear Crankcase Cover15. Rear Oil Seal16. Flywheel Housing17. Flywheel Housing Plate Cover18. Flywheel Housing Baffle (If

Equipped)19. Main Bearing Cap (5)

20. Main Bearing Cap Stud (1)21. Short Mounting Bolt (10)22. Long Mounting Bolt (9)23. Pipe Plug (4)24. Piston Cooling Tube (8)25. Pipe Plug (2)26. Dowel Pin (2)27. Pipe Plug (5)28. Plug (3)29. Dowel Pin (2)




Figure 247 Crankshaft, Flywheel Or Flexplate, And Related Components

1. Crankshaft Gear2. Crankshaft Key (2)3. Crankshaft Bearings (Nos. 1, 2,

3 and 4)4. Thrust Bearing No. 55. Crankshaft6. Coiled Spring Pin7. Flywheel Ring Gear

8. Flywheel (Manual transmission)9. Flywheel Adapter (Automatic

Transmission)10. Flexplate (Automatic

Transmission)11. Reinforcement Ring (Automatic

Transmission)




Figure 248 Connecting Rods, Pistons and Rings

1. Piston Ring Set2. Piston3. Piston Pin4. Retainer Rings5. Piston Assembly6. Pin Bushing7. Connecting Rod8. Connecting Rod Bearings9. Connecting Rod Bolts (2)10. Connecting Rod Nuts (2)

Flywheel and Flywheel HousingRemoval

Figure 249 Removing the Flywheel

1. Flywheel and Ring Gear Assembly2. Flywheel Mounting Bolts (10)3. Guide Studs

NOTE: For automatic transmissions with the olderstyle flexplate: remove the reinforcement ring,flexplate, and adapter before removing the flywheel.For automatic transmissions with the newer styleflexplate, there is no flywheel. The ring gear isinstalled directly onto the flexplate.

1. Remove two flywheel mounting bolts, one at the 3o’clock position and one at the 9 o’clock position.Install two guide studs in their place.

2. Remove the remaining flywheel mounting bolts.Slide the flywheel out of housing and off the guidestuds. With the flywheel removed, the guide studscan be removed.




Figure 250 Removing the Flywheel HousingFlange Bolts

3. Remove six flywheel housing flange mountingbolts and slide the flywheel housing off thecrankcase dowels.

Cleaning

Clean the flywheel with a non-caustic solvent. Dry theflywheel with filtered compressed air.

Inspection

WARNING: A crack or heat check in theflywheel could cause it to separate and injurethe operator or bystanders. If any damage isfound, discard the flywheel.

1. Inspect the flywheel for cracks, heat checks, andextensive scoring which would make it unfit forfurther use. Replace the flywheel if any of thesedefects are found or suspected.

2. Inspect the ring gear for worn, chipped or crackedteeth. If the teeth are damaged, replace the ringgear or flexplate depending on vintage.

Resurfacing (Manual Transmissions)

Figure 251 Flywheel Reconditioning

1. Flywheel Dimensions (NEW – 45.822 mm ± 0.254mm (1.804 ± 0.010 in)) (Minimum Permissible AfterResurfacing 36 mm (1.430 in))

2. Clutch Disc and Cover Plate Mounting Face3. Crankshaft Flange Mounting Face

Flywheel machining information is provided forguidance only. International Truck and EngineCorporation assumes no responsibility for the resultsof any work performed in accordance with thisinformation or for the ability of service personnel todetect heat cracks.




WARNING: To avoid personal injuryand possible death, observe the followingwarnings:

• Resurfacing should be carried out bya skilled technician using specializedequipment for this function.

• The flywheel may be ground to correctminor wear and scoring. New flywheelshave a thickness of 45.822 mm ± 0.254mm (1.804 ± 0.010 in). DO NOT grindbeyond the minimum permissiblethickness of 44.907 mm (1.768 in).Replace the flywheel if it is not repairableby surface grinding.

• Remove material from clutch face only.

After resurfacing, check the flywheel for cracksand heat checks. If any cracks or heat checks aredetected, replace the resurfaced flywheel with a newone.

Installation of Flywheel Housing

Figure 252 Installing the Flywheel Housing

1. Flywheel Housing Mounting Bolts2. Torque Wrench

1. Slide the flywheel housing onto the guide pins.

2. Install six flywheel housing mounting bolts fingertight to secure the housing to the crankcase.

3. Tighten the mounting bolts to the standard torquevalue.




Check Flywheel Housing Bore Concentricity

CAUTION: Bore concentricity and facerunout checks are performed to ensureproper engine to transmission alignment.Improper bore concentricity and face runoutmay result in reduced transmission life.

Figure 253 Checking the Flywheel Housing BoreConcentricity

1. Dial Indicator2. Indicator Tip3. Magnetic Base

1. Attach a dial indicator magnetic base to thecrankshaft and place the indicator tip against theflywheel housing bore.

2. Zero the dial indicator.

3. Rotate the crankshaft slowly and record thetotal indicator variation. Compare the resultto the specification for flywheel housing boreconcentricity.

Check Flywheel Housing Face Runout

Figure 254 Checking the Flywheel Housing FaceRunout

Keep crankshaft end play at zero in the same directionfor all measurements.

1. Attach a dial indicator magnetic base to theflywheel and place the indicator tip againsthousing face.

2. Measure at four points 90 apart for a totalface variation. Compare the average to thespecification for the flywheel housing face runouttolerance.




Check Flywheel Surface Runout

Figure 255 Checking Flywheel Surface Runout

1. Attach a dial indicator magnetic base to theflywheel housing and place the indicator tipagainst the flywheel surface.

2. Rotate the crankshaft slowly and record the totalindicator variation. Refer to the specification forthe tolerance.

Check Crankshaft Pilot Concentricity

1. Attach a dial indicator magnetic base to theflywheel housing and place the indicator tipagainst the flywheel pilot.

2. Rotate the crankshaft slowly and record the totalindicator variation. Refer to the specification forconcentricity tolerance.

Installation of Flywheel

Figure 256 Installing the Flywheel

1. Flywheel and Ring Gear2. Flywheel Mounting Bolts3. Guide Studs

1. Install a flywheel guide stud into the 3 o’clock and9 o’clock positions of the crankshaft.

2. Install the flywheel over the guide studs. Securethe flywheel to the crankshaft with eight mountingbolts finger tight.

NOTE: For automatic transmissions with the olderstyle flexplate, install the flywheel adapter, flexplate,and reinforcement ring onto the flywheel. Make surethe lip of the reinforcement ring is facing outward.Then install the eight mounting bolts.

For automatic transmissions with the newer styleflexplate, there is no flywheel. The ring gear isinstalled directly onto the flexplate.

3. Remove the two guide studs and install theremaining two mounting bolts. Tighten all tenbolts to the special torque value.




Rear Oil Seal and Wear SleeveRemoval

Rear Oil Seal

Figure 257 Flywheel Housing Baffle (if equipped)

1. Mounting Bolts (3)2. Flywheel Housing Baffle

1. If not already done, remove the flywheel fromthe housing. Refer to “Flywheel and Housing —Removal” in this section.

2. If equipped, remove the three mounting boltssecuring the flywheel housing baffle to theflywheel housing.

3. Remove the flywheel housing baffle.

Figure 258 Rear Oil Seal Mounting Bolts

1. Rear Oil Seal/Retainer2. Mounting Bolts (5)

4. Remove five bolts that secure the rear oil seal tothe rear crankcase cover.

Figure 259 Cutting Through RTV Sealant

1. Hammer2. Rear Crankcase Cover3. RTV Cutting Tool4. Seal/Retainer




5. Use a cutting tool to cut through the RTV sealanton the rear oil seal.

6. Remove the rear oil seal from the crankshaft andrear cover plate.

Wear Sleeve

Figure 260 Installing the Wear Sleeve RemovalTool

1. Wear Sleeve Removal Tool2. Forcing Screw

1. Mount the wear sleeve removal tool around thewear sleeve on the crankshaft flange.

2. Turn the forcing screw to remove the wear sleeve.

Figure 261 Removing the Wear Sleeve

1. Wear Sleeve Removal Tool2. Wear Sleeve3. Crankshaft

3. Discard the wear sleeve and inspect thecrankshaft flange for damage.

Installation

NOTE: If the rear cover is going to be removed, do notinstall the rear oil seal until the rear cover is installed.

Figure 262 Installing the Rear Oil SealInstallation Tool

1. Alignment Dowels2. Installation Tool3. Rear Crankcase Cover




1. Install the rear oil seal installation tool onto thecrankshaft flange. Install two rear seal alignmentdowels.

2. Apply RTV sealant to the outer diameter of thecrankshaft seal flange. Also apply a bead of RTVsealant around each bolt hole and the insidediameter of the bolt hole pattern to the crankshaftseal flange.

Figure 263 Installing the Rear Oil Seal

1. Alignment Dowel2. Crankshaft Seal Flange3. Pilot Or Centering Tool

3. Place the seal and wear sleeve assembly over thecentering tool and position the seal retainer overthe alignment dowels. Make sure the seal retainerand crankcase dowels align as the seal is beinginstalled.

Figure 264 Installing the Rear Oil Seal Driver

1. Seal/Retainer2. Installation Tool

4. Install the driver over the centering tool. Tightenthe forcing screw to drive the wear sleeve and rearseal into position.

Figure 265 Installing the Rear Oil Seal

1. Seal/Retainer2. Rear Oil Seal Retainer Bolts (5)

5. Install the retainer bolts. Tighten the bolts to thestandard torque value.




Rear CoverRemoval

CAUTION: To avoid damage to the rear cover,make sure the rear oil seal is removed. Referto “Rear Oil Seal and Wear Sleeve” in thissection.

Figure 266 Removing the Rear Cover

1. Dowel Pins2. Rear Cover Bolt Locations (8)

1. Remove rear cover mounting bolts.

2. Gently pry the rear cover away from crankcase,breaking the RTV sealant bond in the process. Donot bend the rear cover.

Cleaning

1. Use a scraper or wire brush to remove the RTVsealant and any foreign material from the rearcover/oil pan mating surfaces.

2. Use a commercially available brake cleanerto clean the crankcase and rear cover gasketsurfaces. The surfaces must be free of oil forgood adhesion of RTV sealant during installation.

3. Wipe and dry the surfaces with a clean shop cloth.

Installation

CAUTION: If the rear cover is bent, replace it.Failure to do so may result in engine damage.

1. Replace any missing or damaged dowel pins.

Figure 267 Applying RTV to the Rear Cover

1. Rear Cover2. RTV Sealant3. Rear Cover Groove

2. Apply RTV sealant to the groove in the rear coverand around the bolt and dowel pin holes.

3. Place the rear cover over alignment dowels andagainst the crankcase and install the mountingbolts. Tighten the mounting bolts to the standardtorque value.

4. Install the rear oil seal.

Connecting Rods, Pistons andPiston RingsCheck Piston Protrusion

CAUTION: Lack of protrusion could indicatea damaged rod or a rod bearing out ofposition. Excessive protrusion may requirereplacement of rods or crankshaft. To avoidengine damage correct as required.




NOTE: Before removing any piston and connectingrod assemblies, it is recommended that pistonprotrusion be evaluated. This will help identify bentor twisted connecting rods.

1. Check piston protrusion above crankcase asfollows:

2. Turn the crankshaft so the piston is just belowcrankcase deck surface.

3. Place and zero a dial indicator gauge oncrankcase deck surface.

4. Position tip of dial indicator gauge onto the pistonhead at the 3 o’clock position. (Positioning the dialindicator tip at 12 o’clock or 6 o’clock will not yieldan accurate measurement).

5. Turn the crankshaft so the piston is at the highestpoint of its stroke and record the reading.

6. Turn the crankshaft to reposition the piston to justbelow the crankcase surface.

7. Reposition dial indicator tip onto piston head at the9 o’clock position.

8. Turn the crankshaft so the piston is at the highestpoint of its stroke and record the reading. Thenaverage the two readings.

Checking Connecting Rod Side Clearance

Use a feeler gauge to check connecting rod sideclearance as follows:

1. Pry apart a pair of connecting rods on a crankshaftrod journal. Insert largest feeler gauge to checkclearance.

2. Repeat for each pair of connecting rods oneach crankshaft rod journal and compare withspecifications.

Removal

CAUTION: To avoid piston damage, if acarbon ridge is evident at the top of thecylinder bore, remove carbon ridge priorto removing the connecting rod and pistonassemblies. This reduces the chance ofpiston ring land damage during removal.

1. Use a razor knife or emery board to scrape carbonridge from top of cylinder bore.

CAUTION: For newer style connecting rods,keep the fractured mating surfaces cleanand free of lint and debris. Do not allowthe mating surfaces to rest on any surface.Do not bump the mating surfaces or dropthe connecting rod or cap. This couldcause chipping and wear on the matingsurface, resulting in improper mating duringinstallation and possible engine damage.

Figure 268 Connecting Rod Locations

1. Connecting Rod Nuts or Bolts (16)2. Connecting Rod (8)3. Crankshaft4. Connecting Rod Location Mark5. Connecting Rod Cap (8)

2. Rotate crankshaft to position journals for removalof connecting rod assemblies.

3. Mark each connecting rod and its respective rodcap with the cylinder number before removingthem from the engine. Also mark the rod caps forcorrect orientation to each rod.




Figure 269 Removing the Connecting Rod Cap

1. Connecting Rod Cap2. Connecting Rod Nut or Bolt

CAUTION: There are two style connectingrods being used:

• Older style connecting rods usemounting nuts. The mounting nutsshould turn freely off the connectingrod studs. If binding exists, check forbent or damaged threads to avoid enginedamage.

• Newer style connecting rods useself-retained bolts. Connecting rod boltsshould turn freely. If binding exists,check thread condition carefully duringinspection to avoid engine damage.

4. Unscrew the two connecting rod mounting nuts orbolts. Remove the connecting rod cap.

5. Remove the piston and connecting rodassemblies from the crankcase as follows:

a. Rotate the engine into a vertical position (frontend up).

Figure 270 Installing the Connecting Rod GuideProtector Caps (Old Style Connecting Rod)

1. Connecting Rod Nut (16)2. Connecting Rod Cap (8)3. Connecting Rod (8)4. Connecting Rod Guide Protector Caps (2)5. Crankshaft

b. Old style connecting rods: install aluminumconnecting rod guide protector caps over theconnecting rod studs to prevent damage tothe crankshaft rod journals.

Figure 271 Pushing the Old Style ConnectingRod and Piston Out Of the Cylinder Bore

1. Wooden Handle2. Protector Cap3. Connecting Rod4. Crankcase




Figure 272 Pushing the New Style ConnectingRod and Piston Out Of the Cylinder Bore

c. Use a wooden or plastic handle to push theconnecting rod and piston assembly out of thecylinder bore.

Figure 273 Removing Old Style Piston andConnecting Rod Assembly from Crankcase

Figure 274 Removing Piston and ConnectingRod Assembly from Crankcase

d. Once the piston rings are free of the cylinderbore, remove the assembly from the top of thecrankcase.

6. Mark each connecting rod and its respectivebearing cap with the cylinder number from whichthey were removed.

CAUTION: On engines using fracturedconnecting rods: DO NOT alter or damagethe fractured mating surfaces of theconnecting rod and cap.

Figure 275 Matching Cap and Connecting RodNumbers

7. Upon removal, make sure matching connectingrod and cap remain together as a set. A cap fromone connecting rod is not interchangable with anyother connecting rod.




Disassembly

CAUTION: To avoid engine damage, markthe pistons with the cylinder number fromwhich each was removed. Each piston mustbe reinstalled into its original cylinder boreif the pistons are being reused.

CAUTION: To avoid engine damage, make anote of the engine serial number (stampedon the crankcase pad, left side rear of thecrankcase) and piston part number (stampedon the piston crown). There are multiplepistons available for service applications.Do not install any pistons unless they allhave matching part numbers.

Replacement of the flywheel / flexplate andvibration damper may also be necessarydepending on engine serial number. Someengines have pistons with a greater mass,resulting in the need for a flywheel / flexplateand vibration damper with inertia values thatcompliment the additional mass. See yourInternational® Dealer for details.

Figure 276 Removing the Piston Rings

1. Piston Ring Expander Tool2. Piston3. Piston Ring4. Connecting Rod

1. Use a piston ring expansion pliers to remove thepiston rings. Remove the top ring first, then theintermediate ring, and finally the oil control ring.

WARNING: To avoid personal injury,wear safety glasses when removing retainingrings.

Figure 277 Removing the Piston Retaining Ring(New Style Connecting Rod Shown)

2. Separate the connecting rod from the piston asfollows:

a. Use piston retaining ring pliers to remove thetwo piston pin retaining rings.

b. Remove the piston pin from the bore by hand.

c. Separate the connecting rod from the piston.

3. Repeat procedure for each piston / connecting rodassembly which needs to be disassembled.

Cleaning

NOTE: Never use a caustic solution or a wire brush toclean aluminum pistons. Never use a bead blaster onpistons.

1. Use a soap and water solution to clean thealuminum pistons. Soak the pistons, then cleanthe piston with a nonmetallic brush.

2. Clean all piston ring grooves thoroughly.




3. The following disassembled components may becleaned using a suitable solvent.

• Piston pins

• Piston pin retainers

• Connecting rods

4. Thoroughly clean all connecting rod bolt holes andthreads.

Inspection

1. Inspect the pistons for scuffed or scored skirts,cracked or worn ring lands, and cracked or scuffedpin bores. Replace as required.

NOTE: Faulty piston rings cannot always be detectedby visual inspection. Therefore, whenever a piston isremoved from a cylinder, it is recommended that thepiston rings be replaced.

2. Inspect the new piston rings for cleanliness.

3. Inspect the connecting rod studs or bolts for nicksand damage.

4. Inspect the connecting rod and cap matingsurfaces for fretting. The bore must be smoothand free of scoring or nicks. Replace as required.

5. Inspect the piston pins for corrosion or wear.Replace as required.

Check Width of Top Compression Ring Groove

NOTE: Top compression ring groove is a keystonedesign which requires measurement over gauge pinsto determine ring groove wear.

Figure 278 Measuring Top Compression RingGroove

1. Piston gauge pins

1. Check top compression ring groove for wear asfollows:

CAUTION: There are two different sizegauge pins to be used as follows:

• On old style connecting rod andpiston assemblies use 3 mm (0.115in.) gauge pins.

• On new style connecting rod andpiston assemblies use 2 mm (0.082in.) gauge pins.

A. Install a piston gauge pin from the pistongroove wear gauge pin set into the topring groove to be measured. Pistongauge pin must be parallel.

B. Use an outside micrometer to measurediameter over piston gauge pins.

C. If measurement over the gauge pin is notwithin specifications, excessive pistongroove wear exists. Replace piston.




Checking Side Clearance Of Oil Control Ring AndIntermediate Compression Ring Groove

Figure 279 Checking Side Clearance Of TheIntermediate Ring And Oil Control Ring Grooves

1. Compression ring groove2. Intermediate compression ring groove3. Feeler gauge

1. Check side clearance of intermediate ring grooveas follows:

• Place outer edge of new ring in the immediatering groove.

• Roll ring entirely around piston in itsrespective groove. Make sure ring is able tomove freely in its groove.

• Use a feeler gauge to check side clearance ofeach ring in its respective groove.

2. Check side clearance of oil control ring groove asfollows:

• Place outer edge of new ring in oil control ringgroove.

• Roll ring entirely around piston in itsrespective groove. Make sure ring is able tomove freely in groove.

• Use a feeler gauge to check side clearance ofoil control ring in its respective groove.

A. Tight side clearance may indicatecarbon build up in the ring groove.Ring should be cleaned.

B. Excessive side clearance indicatesring groove wear and requires pistonreplacement.

Piston Replacement

Figure 280 Measuring Piston Skirt Diameter

1. Piston Skirt2. 3–4 inch micrometer

When the piston requires replacement, check thecylinder bores. If they exceed the out-of-round ortaper specifications, boring may be required. Suchcylinder bore reconditioning will require the use ofoversize service pistons. Verify the piston size bymeasuring the skirt diameter. See the Specificationsfor the correct measurement location.




Check Piston Ring End Clearance in CylinderBore

Figure 281 Checking the Piston Ring EndClearance in the Cylinder Bore

1. Piston Ring2. Feeler Gauge

NOTE: Faulty rings cannot always be detected byvisual inspection. Therefore, whenever a piston isremoved from a cylinder, replace the piston rings.

1. Inspect piston rings for cleanliness.

2. Before installing new piston rings on piston, checkgap for each ring as follows:

A. Push piston ring down into cylinder bore.Make sure the piston ring is square to thecylinder wall. An inverted piston head canbe used to push piston ring to desiredlocation of measurement (usually at thetop of the piston stroke).

B. Use a feeler gauge to measure the gapbetween the ends of each piston ring.

C. If the gap does not meet the specification,select another piston ring or check thecylinder bore wear again.

Connecting Rods

CAUTION: On newer engines using thefractured connecting rods keep matingsurfaces clean and free of debris.

• DO NOT allow mating surfaces to rest onany other surface.

• DO NOT bump the mating surfaces ordrop the connecting rod or cap.

This could cause wear and chipping of thefractured surface, resulting in impropermating during installation and possibleengine damage.

If the connecting rod cap is reversed whenassembled to the connecting rod or aconnecting rod cap is not installed inits original matching connecting rod, thefractured mating surfaces will be useless.The entire connecting rod assembly must bereplaced.

1. Inspect connecting rod bolts for nicks or damage.Replace as required.

2. Inspect connecting rod and cap mating surfacesand bearing bore for any indication of damage.Bore must be smooth and free of scoring or nicks.Replace as required.




Check Inside Diameter of Piston Pin Bushing

Figure 282 Measuring the Inside Diameter of thePiston Pin Bushing

1. Piston Pin Bushing2. Telescoping Gauge

1. Use a telescoping gauge and an outsidemicrometer, measure the pin bore at two locations90 apart. Record the readings.

2. If the inner diameter of the piston pin bushingexceeds the specification, replace the connectingrod.

Check Connecting Rod Bearing Bore forOut-of-Round and Taper

CAUTION: To avoid engine damage, checkthe connecting rods as follows:

A. On engines equipped with the olderstyle connecting rod, be sure thenuts on connecting rods thread ontothe connecting rod studs by hand. Ifexcessive resistance is felt, clean theconnecting rod studs and try a newnut. If the new nut does not threadon freely, the connecting rod must bereplaced. Failure to do so may resultin engine damage.

B. On engines equipped with thenewer style connecting rod, theconnecting rod bolts should bechecked for binding. The boltsshould thread into the connectingrod freely when lubricated withclean engine oil. If they do not theconnecting rod must be discarded.Connecting rod threads cannot bere-tapped if bonding exists. Checkthread condition carefully duringinspection. Failure to do so mayresult in engine damage.

1. Lubricate the connecting rod nuts or bolts withclean engine oil. Assemble the cap onto itsmatching rod with the bearing insert removed.Tighten the nuts or bolts to the special torquevalue.




Figure 283 Measuring the Connecting RodBearing Bore for Out-of-Round

1. Inside Micrometer2. Connecting Rod Bearing Bore3. Nuts or Bolts

2. Use an inside micrometer (telescoping gauge) tomeasure the connecting rod bearing bore at threelocations approximately 120 apart. Label themA, B and C.

3. If the difference between micrometer reading"B" and the average of reading "A" and reading"C" exceeds the out-of-round specification, theconnecting rod must be replaced.

[(A+C)÷2] – B = actual reading (If the result isnegative, disregard the negative sign.)

4. Check the connecting rod bearing bore taper bymeasuring the bore inner diameter near the largechamfer. Record the reading. Then measurethe bore inner diameter near the small chamfer.Record the reading.

The difference between the two readings is thebore taper. If the connecting rod exceeds thespecification, replace the connecting rod.

5. With the connecting rod cap removed, inspect thesurface finish of the connecting rod bearing bore.The bore must be smooth and free of scoring,nicks and burrs. Replace the connecting rod asrequired.

Check Connecting Rod for Bend or Twist

Often, engine component wear patterns can beidentified and used to diagnose a problem. Some

common examples of connecting rod wear patternsinclude the following:

• A shiny surface on the edge of the piston pinbushing usually indicates that a connecting rod isbent or a piston pin hole is not in proper positionto the piston shirt and ring grooves.

• Abnormal connecting rod bearing wear can becaused by a bent connecting rod, an improperlymachined journal or a tapered connecting rodbore.

• Twisted connecting rods will not create an easilyidentifiable wear pattern, but severely twistedconnecting rods will disturb the action of an entirepiston, ring and connecting rod assembly. It mayalso be the cause of excessive oil consumption.

If any of these conditions exist, use a suitablealignment fixture to check the connecting rods forbends or twists. Follow the instructions of the fixturemanufacturer. If bend or twist exceeds specifications,replace the connecting rod.

Check Piston Pin Clearance

1. Inspect piston pins for corrosion or wear. Replaceas required.

Figure 284 Checking for Piston Pin Wear

1. Piston pin2. 1–2 inch micrometer

2. Use a 1–2 inch micrometer to measure pistonpin outside diameter at two locations 90 apart.Measure each end of the pin. Record the




range of readings. If piston pin wear exceedsspecifications, replace piston pin.

Figure 285 Measuring Piston Pin Bore InsideDiameter

3. Using a 1–2 inch telescoping gauge andmicrometer, measure each piston pin boreinside diameter, at two locations 90 apart.

4. Check piston pin clearance, subtract piston pinoutside diameter from piston pin bore insidediameter measurements. If clearance exceedsspecifications, replace piston pin.

Bearing Fitting Procedure For Old StyleConnecting Rod

CAUTION: To avoid engine damage, do notattempt to reduce journal-to-bearing runningclearances by reworking the bearing capand/or the bearings. Regrind or replace thecrankshaft only.

Figure 286 Effects of Bearing Crush

1. Diameter at Open Ends Before Bearing Crush Load2. Diameter at Open Ends After Bearing Crush Load

Bearing shells must fit tightly in the bore. Whenbearing shells are inserted into the connecting rodand cap, they protrude slightly above the partingsurface. This protrusion is required to achieve abearing crush.

Across the open ends, bearing shells are slightlylarger than the diameter of the connecting rod boreinto which they are assembled. This condition isdesigned into the bearing shell, causing it to spreadoutward at the parting line when a bearing crush loadis applied by tightening the nuts. Some snap may belost in normal use, but bearing replacement is notrequired because of a nominal loss of snap.

When the assembly is drawn up tight, the bearing iscompressed, ensuring a positive contact between thebackside of the bearing and the machined surface ofthe connecting rod bore.

1. Install new bearing shells in the connecting rodand in the bearing cap. Lubricate each shell withclean engine oil.

2. Install the connecting rod on the crankshaft.

3. Install the bearing cap on the connecting rod.Tighten the nuts or bolts on the bearing capalternately and evenly to the special torque value.




Figure 287 Measuring Bearing RunningClearance With Plastigage®

1. Plastigage® Wrapper/Scale2. Connecting Rod Bearing Journal3. Flattened Plastigage®

4. Measure the bearing running clearance asfollows:

a. Remove the bearing cap. Wipe the oil fromthe face of the bearing shell in the bearing capand the exposed portion of the crankshaft.

b. Place a piece of undamaged Plastigage®

across the full width of the bearing shellabout 6 mm (0.25 in) from the center of thebearing cap.

c. Install the bearing cap and tighten the nutsor bolts alternately and evenly to the specialtorque value.

NOTE: Do not turn the crankshaft. This willsmear the Plastigage®.

d. Remove the bearing cap. The Plastigage®

material will adhere to either the bearingshell or the crankshaft. Do not remove thePlastigage®.

e. Use the Plastigage® scale to measure thewidest point of the flattened material. Thenumbers within the graduated marks on thewrapper/scale indicate the running clearancein thousandths of an inch or millimeters. Seethe specifications for the correct runningclearance.

f. Remove the Plastigage® material. Repeat thetest for each connecting rod bearing.

NOTE: With the use of precision bearings, fewproblems should be encountered. However, if properrunning clearance is not achieved, a problem with thecrankshaft may still exist. Regrinding the crankshaftand using undersize bearings are probably necessary.

Also, the bearing cap bolt torque is very important.Use a torque wrench that is known to be accurate.Repeat the running clearance check procedure beforecondemning the crankshaft.

Figure 288 Checking the Connecting Rod SideClearance with a Feeler Gauge

1. Crankshaft2. Feeler Gauge3. Connecting Rod Bearing Cap

5. Measure the connecting rod side clearance usingone of the following tests:

Feeler Gauge Test

Pry two adjacent connecting rods apart and usea feeler gauge to measure the clearance betweenthem. Refer to the specifications and repeat for allconnecting rods.

Dial Indicator Test

a. Place the tip of the dial indicator on theconnecting rod bearing cap.

b. Pry the two connecting rods apart with ascrewdriver or prying tool. Then zero the dialindicator.




c. Pry the connecting rod in toward the dialindicator while recording the connecting rodside clearance. Refer to the specificationsand repeat for all connecting rods.

NOTE: Lack of side clearance could indicate adamaged rod or a bearing that is out of position. Toomuch clearance may require replacement of the rodsor crankshaft.

Assembly – Old Style Connecting Rod

WARNING: To avoid personal injury orpossible death, wear safety glasses wheninstalling piston pin retaining rings.

CAUTION: Make sure the connecting rodand piston are assembled correctly to avoidengine damage. The large chamfer side ofthe connecting rod must be located next tothe crankshaft fillet.

Make sure the lock slots and forging featureon the connecting rod are opposite the“CAM” marking found on the piston head.

Figure 289 Assembly of the Piston andConnecting Rod

1. Piston Stamped “Cam”, Part Number, (ServicePistons Include Oversize Designation)

2. Large Chamfer Side of Connecting Rod

1. Connect the piston to the connecting rod asfollows:

Figure 290 Installing the Piston Pin

1. Piston2. Piston Pin3. Connecting Rod4. Retaining Rings

a. Lubricate the piston pin bore in the connectingrod, the piston bore and the piston pin withclean engine oil.




Figure 291 Installing the Piston Pin RetainingRing

1. Pliers2. Retaining Ring

NOTE: The retaining ring has a smooth finishside and a rough finish side. The smoothfinish side faces the piston pin.

b. Use piston pin retaining ring pliers to installa piston pin retaining ring at one end of thepiston pin bore.

c. Insert the connecting rod into the piston.Make sure the bored holes of the connectingrod and piston are aligned.

d. Slide the piston pin through the bored holes,stopping at the previously installed retainingring.

e. Install the second retaining ring.

Figure 292 Installing Rings Onto Piston

2. Use piston ring expansion pliers to install pistonrings onto piston.

3. Install the oil control ring into the bottom pistongroove.

NOTE: The intermediate ring is identified by the two"OO" marks located on the top surface of the ring. Thetop ring is identified by one single “O” mark locatedon the top surface of the ring. Make sure the ring isinstalled with the identifications marks facing up.

Figure 293 Piston Ring Identification Mark (topring shown)

1. Identification Mark

4. Use the piston ring expansion tool to install theintermediate ring into the middle piston groove.

5. Use the piston ring expansion tool to install the topring into the top piston groove.

6. Space ring gaps approximately 120 apart afterring installation.

Assembly – New Style Connecting Rod

WARNING: To avoid personal injury orpossible death, wear safety glasses wheninstalling piston pin retaining rings.




CAUTION: Make sure the connecting rodand piston are assembled correctly to avoidengine damage. The large chamfer side ofthe connecting rod must be located next tothe crankshaft fillet.

Figure 294 Proper Assembly of the Piston andConnecting Rod

1. Piston Stamped “CAM”’ Part Number, (ServicePistons Include Oversize Designation)

2. Large Chamfer Side of Connecting Rod

1. Connect piston to connecting rod as follows:

Figure 295 Installing the Piston Pin

1. Piston2. Piston Pin3. Connecting Rod4. Retaining Rings

a. Lubricate the piston pin bore in the connectingrod, piston pin bore, and piston pin with cleanengine oil.

Figure 296 Installing Piston Pin Retaining Ring

1. Pliers2. Retaining Ring

NOTE: The retaining ring has a smooth finishside and a rough finish side. The smoothfinish side faces the piston pin.

b. Use pliers to install a piston pin retaining ringat one end of piston pin bore.

c. Insert the connecting rod into the piston.Make sure the bored holes of the connectingrod and piston are aligned.

d. Slide piston pin through bored holes, stoppingat the previously installed retaining ring.

e. Install the second retaining ring.




Figure 297 Piston Ring Locations

1. Top compression ring2. Intermediate compression ring3. Oil control ring

2. Use piston ring expansion pliers to install pistonrings onto piston as follows:

Figure 298 Installing Rings Onto Piston (Typical)

1. Piston ring expander tool2. Piston3. Piston ring (top compression shown)

a. Use the piston ring expansion tool to installthe oil control ring into the bottom pistongroove.

NOTE: The intermediate ring is identified bytwo “OO” marks located on the top surfaceof the ring. The top ring is identified by onesingle “O” mark located on the top surfaceof the ring. Make sure the ring is installedwith the identification mark facing up (top ofpiston).

Figure 299 Piston Ring Identification Mark (topring shown)

b. Use the piston ring expansion tool to installthe intermediate ring into the middle pistongroove.

c. use the piston ring expansion tool to install theto ring into the top piston groove.

3. Space ring gaps approximately 120 apart afterring installation.

Installation – Old Style Connecting Rod

CAUTION: To avoid engine damage:

• DO NOT use any air powered tools wheninstalling and tightening connectingrod nuts. This can cause seizure ofconnecting rod bolts.

• When installing the connecting rod andpiston assembly into the cylinder boreBE SURE TO:

• Install the connecting rod and pistonassemble into the cylinder bore fromwhich it was removed.

• Assemble each connecting rod to theoriginal connecting rod cap.

NOTE: Install the piston and connecting rodassemblies after the piston cooling jets and crankshafthave been installed.




1. Turn the crankshaft so the appropriate crankpin isat the bottom of its stroke.

2. Make sure the connecting rod bearing shellsare properly installed in the bearing cap and theconnecting rod.

Figure 300 Installing Protector Caps on theConnecting Rod Studs

1. Piston and Connecting Rod Assembly2. Protector Caps3. Connecting Rod Bearing Shell (16)

3. Install aluminum protector caps over theconnecting rod studs to help prevent damage tothe crankshaft journals.

4. Coat the cylinder bore, crankshaft journals,pistons, piston rings and the piston installationsleeve with clean engine oil.

5. Before installing the piston into the ringcompressor or the installation sleeve, make

sure the ring gaps are oriented approximately120 apart.

Figure 301 Correct Orientation of a ProperlyInstalled Piston

1. Identification Marking

CAUTION: To avoid engine damage, thearrow located on top of the piston must facethe camshaft side of the crankcase and thelarge chamfer on the connecting rod mustbe positioned next to the crankshaft fillet.




Figure 302 Proper Position of an Installed Connecting Rod

1. Piston Pin Bushing2. Connecting Rod3. Crankshaft4. Crankshaft Fillet

5. Bearing6. Connecting Rod Bearing (upper)7. Connecting Rod Bearing (lower)8. Connecting Rod Bearing Cap

9. Large Chamfer Side (next tofillet)

10. Small Chamfer Side

CAUTION: To avoid engine damage, wheninstalling connecting rod and piston intocylinder bore, be careful not to damage thepiston cooling tube.

6. Install the piston installation sleeve onto thepiston. Make sure the rod bolts are seated.Carefully place the piston and connecting rodassembly into the crankcase bore.




Figure 303 Seating the Piston in the CylinderBore

1. Piston Installation Sleeve2. Piston

7. Use the handle of a hammer and tap the pistoninto the cylinder bore.

8. Remove the aluminum protector caps fromconnecting rod bolts.

Figure 304 Connecting Rod and CapIdentification Marks

NOTE: Make sure each connecting rod is matchedwith the its original bearing cap on the same crankpinfrom which they were removed.

Figure 305 Installing the Bearing Caps

1. Crankshaft2. Bearing Shell3. Connecting Rod

9. Coat the bearing shell surfaces and connectingrod threads with clean engine oil. Install thebearing cap on the connecting rod.




Figure 306 Securing the Connecting Rod Cap

1. Connecting Rod Nuts (16)2. Connecting Rod Bearing Cap (8)3. Crankshaft4. Connecting Rod (8)

10. Install and tighten the connecting rod mountingnuts to the special torque value.

11. Check the piston protrusion above the crankcase.

12. Repeat the installation procedure for theremaining connecting rods and pistons.

Installation – New Style Connecting Rod

CAUTION: To avoid engine damage:

• DO NOT use any air powered tools wheninstalling and tightening connectingrod bolts. This can cause seizure ofconnecting rod bolts.

• When installing the connecting rod andpiston assembly into the cylinder boreBE SURE TO:

• Install the connecting rod and pistonassemble into the cylinder bore fromwhich it was removed.

• Keep the fractured mating surfacesclean and free of lint and debris.Do not allow the mating surfacesto rest on any surface. Do notbump the mating surfaces or dropthe connecting rod or cap. Thiscould cause chipping and wear onthe mating surface, resulting inimproper mating during installationand possible engine damage.

• If the rod cap is reversed whenassembled to the connecting rodor a rod cap is NOT installed on itsoriginal matching connecting rod,the fractured mating surfaces willbe ruined. This may cause the rodcap to come loose and cause enginedamage. The entire connecting rodmust be replaced.

NOTE: Install the piston and connecting rodassemblies after the piston cooling jets and crankshafthave been installed.

1. Turn crankshaft so the appropriate crankpin is atthe bottom of its stroke.

2. Make sure the connecting rod bearing shellsare properly installed in the bearing cap and theconnecting rod.

3. Coat piston and piston rings with clean engineoil. Coat cylinder walls, crankshaft journals, andpiston cope with clean engine oil. (The cope is




a special tool designed to hold the piston rings inplace during installation.)

Figure 307 Correct Orientation of a ProperlyInstalled Piston

1. Identification Marking

CAUTION: To avoid engine damage, thearrow located on top of the piston must facethe camshaft side of the crankcase and thelarge chamfer on the connecting rod mustbe positioned next to the crankshaft fillet.

Figure 308 Installing the Piston and ConnectingRod Into the Cylinder Bore

1. Piston Installation Sleeve2. Piston3. Connecting Rod

4. Place the piston with rings and connecting rodinstalled, into the cope.

5. Install bearing shells into connecting rod and cap.Coat bearing shell in connecting rod with cleanengine oil.

CAUTION: To avoid engine damage, wheninstalling connecting rod and piston intocylinder bore, be careful not to damage thepiston cooling tube.

6. Carefully insert connecting rod and piston intocylinder bore.




Figure 309 Seating the Piston in the CylinderBore

1. Piston Installation Sleeve2. Piston

7. Once piston and connecting rod have beeninserted into the cylinder bore, use the handleof a hammer to tap piston into crankcase bore.Guide connecting rod into place over crankshaftjournal.

NOTE: Be sure each connecting rod is matched withthe original bearing cap on the same crankpin fromwhich they were removed.

Figure 310 Installing the Connecting Rod Cap

1. Crankshaft2. Bearing Shell3. Connecting Rod

8. Coat the bearing shell and connecting rodsurfaces with clean engine oil. Install the bearingcap on the connecting rod.

Figure 311 Securing the Connecting Rod Cap

1. Connecting Rod Nuts or Bolts (16)2. Connecting Rod Bearing Cap (8)3. Crankshaft4. Connecting Rod (8)

9. Install and tighten the connecting rod mountingnuts or bolts to the special torque value.

10. Repeat installation procedure for remainingconnecting rod and piston assemblies.

11. Check connecting rod side clearance with feelergauge. Refer to “REMOVAL” in this section for thecorrect procedure.

Crankshaft and Main BearingsRemoval

NOTE: Crankshaft bearing caps are numbered fromthe front to identify their respective positions forinstallation. The No. 5 bearing cap accommodates athrust flange to limit crankshaft end play.




Figure 312 Removing the Main Bearing Cap

1. Main Bearing Cap Bolt2. Main Bearing Cap

1. Loosen the main bearing cap mounting bolts.

2. Grasp the main bearing cap mounting bolts androck them back and forth to loosen and removethe cap.

3. Remove the lower bearing shell from the mainbearing cap. Keep each shell with its original capfor main bearing inspection.

WARNING: To avoid engine damage,serious personal injury or possibly death,use an appropriate lifting sling whenremoving the crankshaft from the crankcase.

Figure 313 Removing the Crankshaft From theCrankcase

1. Lifting Sling2. Crankshaft

4. Attach a lifting sling to the crankshaft. Lift thecrankshaft straight up and out of the crankcase.

5. Remove the upper main bearing inserts bypushing them out of the main bearing saddle.Mark the upper shells and put them with the lowershells for a proper inspection.

Cleaning

1. Clean the crankshaft with a suitable solvent. Drythe crankshaft with filtered compressed air.

2. Use a stiff nylon brush to clean all of theinternal oil passages of the crankshaft. Loosenall dirt, sludge, and other deposits that mayhave accumulated. Flush the oil passages with asuitable non-caustic solvent. Dry the oil passageswith filtered compressed air.

3. Clean the bearing caps and inserts thoroughly insolvent. Dry with filtered compressed air.




Inspection

Figure 314 Measuring the Crankshaft Journals

1. Micrometer2. Crankshaft

1. Inspect the crankshaft journals (main andconnecting rod) for scratches, grooves andscoring. Use the dye penetrant method whenchecking for cracks.

2. Inspect all bearing inserts. Replace any mainbearings that are scored, chipped or worn.

3. Use a micrometer to measure the diameter ofeach journal.

Check Crankshaft Journals for Out-of-Round andTaper

1. To check for an out-of-round condition, measureeach end of each journal at two points, 90 apartfrom each other (4 measurements total).

NOTE: When taking crankshaft measurements, itis important to keep the micrometer clear of thecrankshaft fillet radius.

a. Take the first two measurements taken in thesame position (one measurement at each endof the journal) and record the average.

b. Again, take the second set of measurementstaken in the other position (at 90 to the firstset, one measurement at each end of thejournal) and record the average.

c. Subtract the smaller averaged value fromthe larger averaged value. This will yield theamount of out-of-round.

2. To determine journal taper, use themeasurements taken in Step 1.

a. Record the average of two measurementstaken at one end of the journal.

b. Record the average of the other twomeasurements at the other side of thejournal.

c. Subtract the smaller averaged value fromthe larger averaged value. This will yield theamount of taper from one end of the journalto the other.

CAUTION: If any journals exceed eitherthe maximum out-of-round or maximumtaper specifications, the crankshaft mustbe replaced or reground and undersizebearings installed. Failure to do so mayresult in engine damage.

Installation of Crankshaft

NOTE: Make sure the crankcase has been inspectedbefore installation.

1. Use a lint-free cloth to wipe any oil off thecrankcase bearing supports.

2. Clean the bearing inserts and bearing capsthoroughly in solvent. Dry them with filteredcompressed air.

3. Inspect each bearing. Replace any bearings thatare scored, chipped or worn.




Figure 315 Lubricating the Upper Main BearingInserts

1. Crankcase2. Main Bearing Insert

4. Lubricate the upper main bearing inserts withclean engine oil and insert them into thecrankcase main bearing supports.

NOTE: Make sure the locking tabs on the bearingsare aligned with the slots in the crankcase saddle.Also, the oil holes in the bearing shells must lineup with the oil holes in crankcase.

WARNING: To avoid engine damage,serious personal injury or possibly death,use an appropriate lifting sling wheninstalling the crankshaft into the crankcase.

Figure 316 Installing the Crankshaft Into theCrankcase

1. Lifting Sling2. Crankshaft

5. Attach an appropriate lifting sling to the crankshaftand carefully lower it onto the main bearing saddlein the crankcase.

Main Bearing Fitting Procedure

1. Install all of the main bearing caps. Tighten themounting bolts to the special torque value.

2. Remove one bearing cap and insert. Leave theremaining caps tight while checking the fit of thebearing with the cap removed.

3. Clean the bearing surface and the exposed half ofthe crankshaft journal. Make sure these surfacesare free of oil.

4. Place a piece of Plastigage® across the full widthof the bearing surface on the crankshaft journal orbearing cap insert approximately 6 mm (.250 in)off center. Install the main bearing cap and tightenmounting bolts to the special torque value.

NOTE: Do not turn the crankshaft while thePlastigage® is on the journal.




WARNING: In chassis service only,before checking for bearing oil clearance,the crankshaft must be supported and heldup against the upper main insert bearinghalves. Failure to do so may result inincorrect oil clearance values and maycause personal injury or engine damage.

Use a jack and a piece of wood aroundthe center of the crankshaft to provideadequate support. The oil clearancechecking procedure is performed exactlythe same as an engine that is mounted onan engine stand.

5. Remove the main bearing cap and insert. Do notdisturb the Plastigage®.

Figure 317 Checking the Bearing Clearance ofthe Crankshaft Journal

1. Oil Clearance Scale2. Main Bearing Journal3. Flattened Plastigage®

6. Use the Plastigage® scale located on theenvelope/wrapper, measure the widest point ofthe flattened Plastigage®. This reading indicatesthe bearing running oil clearance in thousandthsof an inch or millimeter.

7. If the bearing running oil clearance is not withinspecifications, the crankshaft must be replacedor machined and undersized bearings installed.Refer to Crankshaft in this section.

8. Perform this procedure for each main bearing.Then continue on to Installation of Main BearingCap.

Installation of Main Bearing Caps

NOTE: Make sure the bearing oil clearance isacceptable before installing the main bearing caps.

1. Clean the Plastigage® from the main bearing andcrankshaft journal surfaces.

2. Apply clean engine oil to the main bearing capinserts, crankshaft journals and main bearing capmounting bolts.

CAUTION: To avoid engine damage, makesure the main bearing caps are installed inthe proper order. Do not mix them. Capsmust be installed with the stamped arrowfacing the front of the engine. The No. 1location is at the front of the engine.

3. Place the No. 1 through No. 4 bearing caps intoposition. Install the mounting bolts finger tight.

4. Use a soft hammer to tap the bearing caps untilthe rear machined faces of the caps are flush withthe machined faces of the crankcase.

CAUTION: Make sure the rear thrust flangesare flush with each other. Aligning the mainbearing caps in this manner will ensureproper cap location and may prevent enginedamage.

5. Install the No. 5 rear thrust bearing cap intoposition. Install the mounting bolts finger tight.




Figure 318 Tightening the Main Bearing CapMounting Bolts

1. Mounting Bolt2. Main Bearing Cap3. Crankshaft4. Crankcase

6. Tighten the mounting bolts for main bearing capsNo. 1 through No. 4 to the special torque value.

Check Crankshaft End Play

NOTE: The main thrust bearing cap (No. 5 mainbearing) provides the initial location of the crankshaftend thrust in relation to the crankcase.

1. Mount a dial indicator on the crankcase with theindicator tip on the crankshaft gear.

2. Use a pry bar or equivalent to pry the crankshaftback and forth.

3. Tighten the mounting bolts of the No. 5 thrustbearing cap to the special torque value.

Figure 319 Checking the Crankshaft End Play

1. Pry Bar2. Dial Indicator3. Crankshaft Gear

4. Pry the crankshaft forward and zero the dialindicator. Check the end play by prying thecrankshaft backward and reading the dialindicator. Repeat the procedure to ensurethe accuracy of previous results.

5. After checking the crankshaft end play, one of thefollowing will occur:

• The crankshaft end play is withinspecifications, installation is complete.

• The crankshaft end play exceedsspecifications, replace the main thrustbearing and check the crankshaft end playagain.

• The crankshaft end play is less than theminimum specified limit, the main thrustbearing faces are damaged or dirty. Replaceor clean the main thrust bearing and checkcrankshaft end play again.

• If the main thrust bearing is not damaged ordirty, it was probably misaligned. Removethe main thrust bearing and repeat installationprocedure again.




Piston Cooling JetsRemoval

Figure 320 Piston Cooling Jet

1. Piston Cooling Jet2. Mounting Bolt

Remove the mounting bolt that secures each pistoncooling jet to the crankcase. Remove the pistoncooling jets.

Cleaning and Inspection

1. Replace any piston cooling jets that are crackedor bent.

2. With the piston cooling jets removed, run anappropriate size wire through each tube toensure there is no blockage.

3. Use filtered dry compressed air to blow out anydebris from cleaning.

Installation

CAUTION: The piston cooling jets use aspecial patch type mounting bolt. Do notsubstitute or the mounting bolts will nottighten properly. This can cause the coolingjet tubes to become misaligned, or loosenand fall into the crankcase, causing severeengine damage.

If the original patch bolts are being installed,make sure the bolts threads and bolt holesare cleaned and apply Loctite to the boltsthreads. This will ensure that the patch boltswill not come loose in the engine.

Figure 321 Installing the Piston Cooling Jet

1. Piston Cooling Jet Tube2. Patch Bolt

NOTE: Do not perform Step 1 if new patch bolts arebeing installed.

1. If the original patch bolts are being reused, cleanthe bolt hole and bolt threads so they are free ofoil residue. Apply Loctite® #242 to the threads ofreused patch bolts.

2. Place the piston cooling jet tube onto thecrankcase mounting pad.

NOTE: The bolt-on piston cooling jet tubes are selfaligning.

3. Tighten the patch bolts to the standard torquevalue.




Crankcase ReconditioningCleaning

The best way to clean the crankcase during anengine overhaul is in a chemical bath or HOT TANK.This procedure removes all carbonized materialand mineral deposits which collect in the coolingpassages. However, when a HOT TANK is notavailable, use the following.

NOTE: Thoroughly clean and inspect crankcasebefore and after reconditioning.

1. Use a scraper and a sanding block to clean all oldgasket material from the machined surfaces of thecrankcase.

2. Clean the cylinder bores with soap, water and anylon brush.

3. Remove the pipe plugs on front of crankcase.Thoroughly clean all of the oil passages and boltholes.

4. Remove the main oil gallery plugs. Use a nylonbrush to clean the main oil gallery.

Figure 322 Valve Lifter and Main Oil Gallery PlugLocations

1. Valve Lifter Oil Gallery Plugs2. Main Oil Gallery Plug

5. Remove the valve lifter oil gallery plugs located inthe rear of the crankcase and discard them. Usea nylon brush to clean to clean the valve lifter oilgalleries.

6. Apply Aviation Permatex No. 3 to the main oilgallery plug and install it into the crankcase. Makesure the top of main oil gallery plug is below thesurface level of the crankcase.

7. Apply Aviation Permatex No. 3 to the new valvelifter oil gallery plugs and install them into thecrankcase.

Inspect Short Circuit Valve

Figure 323 Short Circuit Components

1. O-Ring2. Plug3. Spring4. Check Ball

1. Use a hex head wrench to remove the plug locatedin the top left front of the crankcase.

2. Inspect the plug, O-ring, spring, and the check ballfor wear. Also check the ball seat in the valve portof the crankcase. Replace any worn items.

3. Install the ball and spring into the valve port. Applyclean engine oil to the O-ring and place it onto theplug.

4. Screw the plug into the crankcase. Tighten theplug to the standard torque value.

Replace Crankcase Cup Plugs

1. Use a hammer and punch to drive a hole into theside of the cup plug (near the edge). Then pry




out the cup plug. Be careful not to damage theexpansion bore.

2. Use a cup plug driver to install new cup plugs.Coat the edges of the plug with Aviation PermatexNo. 3. The driver installs the plug to the properdepth.

Check Crankcase Surface for Flatness

CAUTION: The threads in the crankcase boltholes must be cleaned and blown dry withfiltered compressed air. Dirt or oil left in theholes may cause binding or a false torquereading during reassembly.

CAUTION: Do not resurface the crankcase.Surface defects beyond those listed arenot correctable. To avoid engine damage,replace the crankcase.

1. After cleaning, inspect the crankcase for scoring,roughness, cracking or wear at the cylinder bores.

Figure 324 Checking the Crankcase Deck forFlatness

1. Straightedge2. Feeler Gauge3. Crankcase

2. Using a straightedge, check the top surface ofthe crankcase for flatness by attempting to inserta 0.10 mm (0.004 in) feeler gauge between thestraightedge and the crankcase head surface.If the gap exceeds 0.10 mm (0.004 in), thecrankcase must be replaced.

Check Cylinder Bore for Out-of-Round and Taper

Figure 325 Checking the Cylinder Bore forOut-Of-Round

1. Check for an out-of-round condition as follows:

a. Measure the diameter of each cylinder boreat the top of the piston ring travel (Dimension"A"). For each cylinder, measure Dimension"A" at a right angle to the center line of thecrankshaft. Record each reading.

b. Measure each cylinder bore so the gaugereading coincides with the centerline of thecrankshaft (Dimension "B"). Record thereading.

c. Subtract the smaller value from the largervalue. The difference in measurements willbe the out-of-round condition at the top of thecylinder bore.

d. Repeat the same procedure at the bottom ofthe ring travel to check for an out-of-roundcondition.




Figure 326 Checking Cylinder Bore Taper

1. Measurement at the top of the cylinder2. Measurement at the bottom of the cylinder

2. Determine the taper of the cylinder bore bycalculating the difference between the diametersof the top and bottom of the cylinder bore.

3. If the cylinder bore is within specifications,standard size pistons and rings may be used.If a cylinder bore is suitable for use withoutreconditioning, deglaze the cylinder bore with aglaze breaking brush and continue with assembly.Refer to Deglazing in this section.

If the cylinder walls have minor surface damage,but are otherwise within specifications, it may bepossible to remove such damage by honing.

If any of the cylinder bores are deeply scoredand exceed any of the out-of-round or taperconditions, machining the cylinders to the nextoversize is necessary.

Deglazing

1. Remove the piston cooling jets. Refer to PistonCooling Jets, Removal for the procedure.

Figure 327 Glaze Breaking Brush

1. Rubber Hose Over Shaft

2. Cylinder bore can be deglazed using a 120 gritglaze breaking brush. Install a 50 mm (2 in)section of rubber hose over the end of the shaft(Figure 327).

This silicone carbide-tipped nylon flexible brushquickly deglazes cylinder walls and produces across-hatch pattern on the cylinder wall surfacein a single operation. The brush contours itself tothe cylinder wall and conditions the wall surfacewithout altering the cylinder bore.

Figure 328 Preparing Glaze Breaking Brush forDeglazing

3. Obtain a 355 ml (12 oz) can of PE-12 Solventand Penetrating Fluid manufactured by AGS(or equivalent), available at any well-stockedauto supply house. This spray contains colloidalgraphite and works well for this application. Sprayboth the cylinder to be deglazed and the glazebreaking brush.




Figure 329 Deglazing the Cylinder Bore

4. Deglaze the cylinder as follows:

a. Attach the glaze breaking brush to a variablespeed electric or air powered drill motor.

b. Deglaze the cylinder wall for about 15seconds while stroking the bore up and downat a rate of one complete up and down strokeper second.

A speed of approximately 100-120 rpm isrequired. Speed adjustment is required forthe procedure to be successful.

c. Withdraw the glaze breaking brush fromthe cylinder bore while the brush is rotating.Wipe a portion of the cylinder wall and inspectthe cross-hatch pattern. Compare it to anuntouched cylinder bore. The crosshatchpattern should be approximately 45 .

d. If the pattern is "flatter" than required,increase the up and down stroke speed orslow down the drill rotation.

e. Continue deglazing the cylinder bore for10-15 seconds or 20-25 strokes.

f. Wipe the cylinder bore clean and inspect thebore for a proper 45 cross-hatch pattern.

5. After deglazing, thoroughly clean the cylinderbores with a soft bristle brush, soap and water.Dry the bores with filtered compressed air andlubricate the bores with clean engine oil.

6. Install the piston cooling jets before assembly.Refer to Piston Cooling Jets, Installation forthe procedure.

Camshaft BushingsCheck for Wear and Proper Running Clearance

1. Use a micrometer to measure each camshaftbearing journal diameter at two locations90 apart. Record the average of these twomeasurements.

2. With the camshaft bushings installed in thecrankcase, use a telescoping gauge andmicrometer to measure each camshaft bushinginner diameter at two locations 90 apart. Recordthe average of these two measurements.

3. Subtract the two averages to determine therunning oil clearance. If the result exceeds thespecification, replace the camshaft bushings.

Removal

CAUTION: When servicing the camshaftbushings, the crankshaft and main bearingsmust be removed from the crankcase toavoid contamination from debris. Such acontamination may result in engine damage.

Figure 330 Assembling and Installing theCamshaft Bushing Removal Tool

1. Pulling Screw2. Expanding Collet3. Backup Nut

1. Use the camshaft bushing removal tool and selectthe proper size expanding collet and backup nut.Assemble the parts onto the expanding mandrel.




2. With the expanding collet collapsed, installthe collet assembly into the camshaft bushing.Tighten the backup nut on the expanding mandreluntil the collet fits on the camshaft bushing.

Figure 331 Attaching the Puller Screw

1. Expanding Mandrel2. Puller Screw

3. Assemble the puller screw onto the expandingmandrel. Wrap a cloth around the threads of thepuller screw to protect the front camshaft bushing.

Figure 332 Installing the Pulling Plate andThrust Bearing

1. Puller Screw2. Backup Nut3. Thrust Bearing4. Pulling Plate

4. Attach the pulling plate, thrust bearing and backupnut to puller screw. Tighten the nut against the

thrust bearing and pulling plate to remove thecamshaft bushing. Hold a wrench on the end ofthe puller screw to prevent it from turning.

Inspection

1. Inspect each bushing bore in the crankcase forburrs or debris that could damage new bushingswhen they are installed.

2. Remove any burrs and clean bores thoroughlybefore installing new camshaft bushings.

Installation

CAUTION: The bushings are interchangeablefrom one bore to another except for the No.1 (front) bushing, which is wider than theothers. To avoid engine damage, identifythe No. 1 (front) bushing from the Nos. 2– 5(intermediate and rear) bushings.

1. Lubricate the new camshaft bushings and thecrankcase bores with clean engine oil.

CAUTION: Failure to use the correctexpanding collet can cause severe bushingdamage.

2. Use the camshaft bushing installation tool toinstall the new bushing onto the expanding collet.Tighten the collet by turning the backup nut untilthe bushing is held securely.

3. Mark the oil hole location on the backup nut ofthe installation tool as an aid in aligning the oilholes in the bushing and crankcase. This stepmust be repeated for each camshaft bushing thatis installed.

CAUTION: To ensure proper oil circulationthroughout the crankcase, make sure allcamshaft bushing oil holes are in alignmentwith the oil holes in the crankcase. Failureto do so may result in engine damage.




4. Install the intermediate and rear camshaftbushings through the front of the crankcase.Then pull them into place from the rear of thecrankcase by turning the pulling nut on the pullerscrew. Remove the installation tool and inspectthe oil hole alignment.

Figure 333 Checking the Camshaft Bushing /Crankcase Oil Hole Alignment

1. Alignment Wire2. Main Bearing Saddle3. Camshaft Bushing Oil Hole

5. After all of the camshaft bushings have beeninstalled, use a wire to verify oil hole alignment.

6. Install the front camshaft bushing by pulling it intoplace from the rear of the crankcase.




SPECIFICATIONS

Table 19 Crankcase, Camshaft Bushing, Crankshaft and Main Bearing, Connecting Rod and Piston

CRANKSHAFT

Main Bearing Journal Diameter

Standard Size 79.3191 - 79.3394 mm (3.1228 - 3.1236 in)

0.254 mm (0.010 in) Undersize 79.0651 - 79.0854 mm (3.1128 - 3.1136 in)



Main Bearing Journal Maximum Out-of-Round 0.00559 mm (0.00022 in)

Main Bearing Thrust Face Runout (T.I.R. maximum) 0.0254 mm (0.001 in)

Main Bearing Journal Taper (max. per inch) 0.381 mm (0.0015 in)

Main Journal Fillet Radius, Journal No. 1, 2, 3 and 4 3.302 mm (0.130 in)

Main Journal Fillet Radius, Journal No. 5 3.99 - 4.14 mm (0.157 - 0.163 in)

Rod Journal Fillet Radius 3.68 mm (0.145 in)

Oil Seal Journal Runout (maximum) 0.05 mm (0.002 in)

Flywheel Housing Bore Concentricity (maximum) 0.20 mm (.008 in)

Flywheel Housing Face Runout (maximum) 0.51 mm (0.020 in)

Flywheel Surface Runout (maximum) 0.05 mm (0.002 in)

Flywheel Thickness (minimum) (See flywheel reconditioningFigure 251.) 44.907 mm (1.768 in)

Thrust Taken By No. 5 Main

Thrust Bearing Journal Length 31.509 - 31.585 mm (1.2405 - 1.2435 in)

Main Bearing Inner Diameter (Installed) 79.385 - 79.436 mm (3.1254 - 3.1274 in)

Main Bearing to Crankshaft Running Clearance 0.046 - 0.117 mm (0.0018 - 0.0046 in)

Connecting Rod Journal Diameter





Connecting Rod Journal, Maximum Out-of-Round 0.0056 mm (0.00022 in)

Connecting Rod Journal Taper (max. per inch) 0.0066 mm (0.00026 in)

Connecting Rod Bearing to Crankshaft Running Clearance 0.038 - 0.114 mm (0.0015 - 0.0045 in)

Crankshaft Flange Outer Diameter 111.05 - 111.15 mm (4.372 - 4.376 in)

Crankshaft End Play 0.063 - 0.216 mm (0.0025 - 0.0085 in)

Crankshaft End Play Maximum Wear Limit 0.51 mm (0.020 in)




Table 19 Crankcase, Camshaft Bushing, Crankshaft and Main Bearing, Connecting Rod and Piston(cont.)

Rod to Crankshaft Side Clearance 0.30 - 0.61 mm (0.012 - 0.024 in)

Crankshaft Straightness (T.I.R. Maximum) 0.10 mm (0.004 in)

Crankshaft Gear Backlash (0.1397 - 0.02794 mm (0.0055 - 0.0110 in)

CRANKCASE

Crankcase Deck Flatness 0.025 mm per 50.8 mm, 0.10 mm Total (0.001in. per 2 inches, 0.004 in Total)

Crankcase Main Bearing Bore Diameter 84.206 - 84.231 mm (3.3152 - 3.3162 in)

Crankcase Cam Bearing Bore Diameter 56.655 - 56.693 mm (2.2305 - 2.2320 in)

Valve Lifter Bore Diameter 23.439 - 23.477 mm (0.9228 - 0.9243 in)

Valve Lifter Outer Diameter 23.391 - 23.411 mm (0.9209 - 0.9217 in)

Oil Jet Tube Bore Diameter (Spray Hole Diameter) 0.91 - 1.32 mm (0.036 - 0.052 in)

Cylinder Bore Taper (Top to Bottom) 0.076 mm (0.003 in)

Cylinder Bore Diameter 104.384 - 104.402 mm (4.1096 - 4.1103 in)

Cylinder Bore Maximum Out-of-Round 0.05 m (0.002 in)

Centerline of Main Bearing Bore to Head Deck 287.73 - 287.83 mm (11.328 - 11.332 in)

Oil Seals (Front and Rear Seal Face Runout With Plates InstalledOn Engine) 0.38 mm (0.015 in) T.I.R. Max.

CONNECTING RODS

Connecting Rod Length Center to Center 181.10 mm (7.130 in)

Bushing Bore Diameter (Pin End) 33.235 - 33.243 mm (1.3085 - 1.3088 in)

Piston Pin Bushing Inner Diameter 32.83 - 32.84 mm (1.2924 - 1.2929 in)

Bearing Bore Diameter (Crankshaft End) 68.339 - 68.364 mm (2.6905 - 2.6915 in)

Bearing Bore Maximum Out-of-Round 0.013 mm (0.0005 in)

Bearing Bore Maximum Taper / Inch 0.013 mm (0.0005 in)

Connecting Rod Bearing Inner Diameter 63.513 - 63.564 mm (2.5005 - 2.5025 in)

Connecting Rod Bearing Running Clearance 0.038 - 0.114 mm (0.0015 - 0.0045 in)

Connecting Rod Side Clearance 0.30 - 0.61 mm (0.012 - 0.024 in)

Twist 0.05 mm/in (0.002 in/in)

Bend 0.025 mm/in (0.001 in/in)

Weight - Complete Rod Without Bearing (Old Style)

Weight - Complete Rod Without Bearing (New Style)

1.058 - 1.446 kg (1058 - 1446 g)

1.202 - 1.216 kg (1201.5 - 1215.5 g)

Pin to Bushing Clearance 0.010 - 0.023 mm (0.0004 - 0.0009 in)

PISTONS





Skirt Diameter — Measure 43 mm (1.684 in) below oil groove, at90 angle to the piston pin. Measure only at room temperature of19-21 C (66-70 F).

104.34 - 104.44 mm (4.108 - 4.112 in)

Service Piston


0.254 mm (0.010 in) Oversize 104.50 - 104.52 mm (4.114 - 4.115 in)



Piston Protrusion Above Crankcase Deck 0.58 – 0.84 mm (0.023 – 0.033 in)

Clearance In Cylinder Bore No. 1 – 8 0.112 - 0.1491 mm (0.0044 - 0.00587 in)

Top compression ring groove width - Measure over 2.92 mm (0.1150 in) gauge pins:

Upper Limit 104.85 mm (4.128 in)

Replacement Limit 104.06 mm (4.097 in)

Piston Pins

Length 75.9 - 76.2 mm (2.99 - 3.00 in)

Diameter 33.220 - 33.226 mm (1.3079 - 1.3081 in)

Pin fit @ room temperature, 19-21 C (66-70 F):

Clearance In Rod 0.010 - 0.023 mm (0.0004 - 0.0009 in)

Clearance In Piston 0.007 - 0.018 mm (0.0003 - 0.0007 in)

End Clearance 0.10 - 0.76 mm (0.004 - 0.030 in)

Piston Rings

Ring Diameter (Standard)

Compression Top (Full Keystone (Barrel Face) Plasma Coated) 104.4 mm (4.11 in)

Compression 2nd (Rectangular Negative Twist - Tapered Face) 104.4 mm (4.11 in)

Oil Control (One Piece Conformable with Chrome ExpanderSpring) 104.4 mm (4.11 in)

Fit in Groove (Side Clearance)

2nd 0.05 - 0.10 mm (0.002 - 0.004 in)

Oil Control 0.023 - 0.074 mm (0.0009 - 0.0029 in)

Ring Gap in Bore

Top 0.35 - 0.61 mm (0.014 - 0.024 in)

2nd 1.57 - 1.82 mm (0.062 - 0.072 in)

Oil Control 0.30 - 0.61 mm (0.012 - 0.024 in)




Special Torque

Table 20 Crankcase, Crankshaft, Connecting Rods and Piston Special Torques

First Step: 71 N·m (52 lbf·ft)Connecting (4 lbf-ft) Rod Mounting Nuts (Old Style)

Final Step: 108 N·m (80 lbf·ft)

First Step: 71 N·m (52 lbf·ft)Connecting Rod Bearing Bolts (New Style)


Flywheel gear access cover bolts 5 N·m (4 lbf-ft)

Flywheel Mounting Bolts 121 N·m (89 lbf·ft)

First Step: 102 N·m (75 lbf·ft)Main Bearing Cap Mounting Bolts


Oil Pick up Tube Flange Bolts 24 N·m (18 lbf·ft)

Piston Cooling Jet Mounting Bolts 11 N·m (100 lbf·in)





Table 21 Crankcase, Crankshaft, Connecting Rods and Piston Special Service Tools

D81L6002B Plastigage®

OEM1000 Micrometer

OEM1022 Telescoping Gauge Set

OEM1023 Telescoping Gauge


OEM1032 Dial Bore Gauge

OEM1293 Straight Edge

OEM6270 120 Grit Glaze Breaker Brush

OEM6453 Piston Retaining Ring Pliers

ZTSE1897E Camshaft Bushing Removal/Installation Set

ZTSE1942A Crankshaft Rear Oil Seal Installation Tool

ZTSE3020 Piston Groove Wear Measuring Tool Set

ZTSE4155A Expansion Plug Replacement Tool

ZTSE4220 Piston Ring Expander

ZTSE4311 Connecting Rod Installation/Remover Guide Pins

ZTSE4317 Crankshaft Wear Ring Removal Tool

ZTSE4318 Rear Oil Seal Installation Tool

ZTSE4375 Flywheel Installation/Removal Guide Studs

ZTSE4385 Oil Pan/Rear Oil Seal Cutting Tool

ZTSE4389 Oil Galley Cleaning Brush



THERMOSTAT AND COOLANT FILTER 209

Table of Contents

Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .212Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .212Testing Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .212Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .213

Coolant Filter and Header. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214Removal (Front of Engine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214Installation (Front of Engine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215




210 THERMOSTAT AND COOLANT FILTER




Figure 334 Water Pump and Thermostat

1. Water Outlet Pipe2. Thermostat with integral seal3. Water Pump Gasket4. Plug, 3/8 NPTF (2)

5. Plug, 3/4 NPTF (2)6. Coolant Filter7. Water Pump Pulley8. Retaining Ring

9. Coolant Filter Shutoff Valve10. O-ring11. Water Pump Assembly12. Plug, 1/2 NPTF




ThermostatRemoval

WARNING: To avoid personal injuryor possibly death, always allow engine tocool first. Wrap a thick, heavy cloth aroundradiator cap. Push down and loosen the capslowly to its first notch position. Then pausea moment. This will avoid possible scaldingby hot water or steam. Continue to turn thecap to the left and remove it.

Figure 335 Thermostat Outlet Tube

1. Coolant Outlet Tube2. Thermostat3. Thermostat Gasket (Square Cross Section)

1. Remove the three bolts that secure the outlet tubeto the water pump housing.

NOTE: Some engines were equipped with athermostat having a separate gasket. Removeand discard thermostat and thermostat gasket.Replace with new thermostat with integral seal. Referto “Installation”.

2. Remove thermostat with integral seal from thewater pump housing.

Testing Operation

WARNING: To avoid serious personalinjury or possibly death, use caution to avoidburns when dealing with hot coolant andobjects. Use heat resistant gloves and wearappropriate eye protection.

CAUTION: When servicing the thermostat, itis essential that the thermostat opens fullyat the specified temperature. A thermostatthat functions properly will reduce the risk ofengine damage caused by overheating.

NOTE: Only genuine INTERNATIONAL® thermostatsensure proper coolant flow and positive sealingcharacteristics. INTERNATIONAL® thermostats arerequired to provide proper engine cooling. Make surethe thermostat is a INTERNATIONAL® thermostatthat has the correct temperature range.

Figure 336 Testing Thermostat Operation

1. Suspension Line2. Ribbon3. Thermometer4. Thermostat5. Heat Source

1. Manually open the thermostat just enough toinsert a nylon ribbon under the valve seat.Suspend the thermostat in a container so thethermostat does not touch the bottom of thecontainer.




2. Heat the container filled with water to theSTART-TO-OPEN temperature. Observe thethermometer and record the temperature as soonas the thermostat drops from the nylon ribbon.This is the actual START-TO-OPEN temperature.

Figure 337 Thermostat Sleeve Travel

1. Typical Thermostat2. Minimum Sleeve Travel

3. Continue to heat the water to the FULL-OPENtemperature. Observe the thermometer andmovement of the thermostat sleeve when theFULL-OPEN temperature is achieved. Theminimum sleeve travel at the FULL-OPENtemperature is 8.0 mm (0.315 in).

4. Remove the thermostat from the container.Quickly inspect the seat area for pitting andforeign deposits before the thermostat closes.

5. Replace thermostat if it does not operate asdescribed or if it does not meet the inspectioncriteria.

Installation

Figure 338 Installing the Thermostat and OutletTube

1. Coolant Outlet Tube2. Thermostat with integral seal

1. Install thermostat with integral seal into the waterpump housing. Make sure the arrow on thethermostat is pointing toward rear of the engineor toward the rear flange bolt.

2. Put the coolant outlet tube on the water pumphousing. To ensure a tight fit, make sure the outlettube flange is not bent or distorted.

3. Install three mounting bolts finger tight. Thentighten the mounting bolts evenly to the standardtorque value.




Coolant Filter and HeaderRemoval (Front of Engine)

WARNING: To avoid serious personalinjury or possibly death, always allow theengine to cool first. Wrap a thick, heavycloth around the radiator cap. Push downand loosen the cap slowly to its first notchposition to relieve any pressure. This willavoid possible scalding by hot water orsteam.

Figure 339 Coolant Filter Located on the Frontof the Engine

1. Shut Off Valve (OFF Position)2. Water Pump Housing3. Coolant Filter

1. Loosen radiator cap.

2. Turn coolant filter shut off valve to OFF.

3. Use a strap type wrench to remove the coolantfilter from the water pump housing.

Installation (Front of Engine)

Figure 340 Coolant Filter Located on the Frontof the Engine

1. Shut Off Valve (OFF Position)2. Water Pump Housing3. Coolant Filter

1. Apply coolant to the gasket of the coolant filter.

2. Install new coolant filter to front cover. Tightenfilter one full turn after the gasket contacts thewater pump housing.

3. Turn coolant filter shut off valve to the OPEN,allowing coolant to flow through the filter.

4. Tighten radiator cap.




SPECIFICATIONS

Table 22 Thermostat and Coolant Filter

Thermostat

Type Poppet Valve, Pellet Operated

Operating Start-to-Open Temperature 89 ± 2 C (192 ± 4 F)

Maximum Full-Open Temperature 104 C (219 F)

Sleeve Travel at Full-Open Temperature 8 mm (0.315 in)

Coolant Filter

Type Spin-On

Length of Filter 106 mm (4.18 in)


Table 23 Thermostat and Coolant Filter Special Service Tools

OEM6413 Strap Wrench



OIL COOLER AND FILTER 217

Table of Contents

Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .220Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .220Leakage Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .220Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221Cleaning.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .222Filling Crankcase With Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .222



218 OIL COOLER AND FILTER




Figure 341 Oil Cooler Assembly

1. Front Header Gasket2. Front Oil Cooler Header3. O-Ring (Thin)4. O-Ring (Thick)5. Oil Cooler Bundle6. Rear Filter Header Gasket

7. Rear Oil Cooler HeaderAssembly

8. Valve, Pressure Regulating9. 6 mm (1/4 in) Hex Head Plug10. Lube Oil Filter




Oil CoolerRemoval

1. Drain coolant from the engine.

Figure 342 Removing Oil Cooler Assembly

1. Oil Cooler Assembly

2. Remove and discard oil filter.

3. Remove oil cooler assembly from crankcase andfront cover mounting pads.

Leakage Test

Inspect oil cooler assembly for leaks by using thefollowing air pressure test:

Figure 343 Air Pressure Test

1. Pressure Gauge and Regulator2. Oil Cooler Front Header3. Test Plate4. Oil Cooler Filter Header

1. Remove heater and block the heater plug.

2. Install a new oil filter and all pipe plugs in theheaders.

3. Fasten oil cooler test plate to oil cooler.

4. Fasten pressure gauge and regulator to test plate.




Figure 344 Oil Pressure Check

1. Test Plate2. Oil Cooler Filter Header3. Oil Cooler Front Header4. Pressure Gauge and Regulator

5. Perform oil pressure check as follows:

a. Leave water side 1/4 NPTF hole in the testplate open.

b. Install an air pressure hose to the oil side ofthe 1/4 NPTF hole in the test plate.

c. Immerse the assembly in a container of cleanwater.

d. Apply 276 – 414 kPa (40 – 60 psi) of airpressure while the assembly is immersed.

e. Inspect the header castings, O-rings andwater side 1/4 NPTF hole for moving orgrowing bubbles. Replace components asrequired.

6. Perform water side oil cooler check as follows:

a. Leave the oil side 1/4 NPTF hole in the testplate open.

b. Install an air pressure hose to the water sideof 1/4 NPTF hole in the test plate.

c. Immerse assembly in a container of cleanwater.

d. Apply 276 – 414 kPa (40 – 60 psi) air pressurewhile the assembly is immersed.

e. Inspect header castings, O-rings and oil side1/4 NPTF hole for moving or growing bubbles.Replace components as required.

Disassembly

Gently tap headers to loosen the O-rings. Twistheaders and separate them from oil cooler bundle.

Cleaning

CAUTION: To avoid engine damage, shoulda bearing failure occur, the oil cooler bundlemust be replaced because debris from afailed bearing cannot be removed from thecooler bundle.

1. Immerse oil cooler, front header and filter headerin a suitable solvent. Flush and drain oil cooler toremove any residue.

2. Dry all components thoroughly with filteredcompressed air.

Inspection

1. Inspect oil cooler for blocked tubes and corrosionwhere the tubes are assembled to the oil coolerbundle. Replace the oil cooler bundle if required.

2. Inspect filter header for blocked orifices anddamaged threads at the oil filter threaded inserts.

3. Remove any debris that may be blocking the oilflow passages.

4. If thread damage is apparent, replace the header.

Assembly

1. Install new O-rings on the oil cooler bundle.

2. Lubricate the oil cooler bundle headers andO-rings with clean engine oil.

3. Carefully press the assembly together. Make surethe header is not cocked and the locating clip ofthe oil cooler rear header is aligned in the slot ofthe cooler bundle.




Installation

Figure 345 Installing the Oil Cooler

1. Oil Cooler Assembly

1. With the oil cooler and headers assembled, installthe assembly with a new gaskets to the left sideof the crankcase. Tighten the bolts to standardtorque.

NOTE: Do not overtighten the filter. A damaged filtermay fracture or leak.

2. Lubricate a new filter gasket with clean engine oil.

3. Spin the oil filter on the threaded adapter until thegasket contacts the oil filter header. Tighten theoil filter an additional 3/4 to 1 turn.

Filling Crankcase With Oil

1. Fill the crankcase with 18.5 L (19.5 qt.) of oil if theoil filter has been changed or 17 L (18 qt.) of oil ifthe oil filter has not been changed. If the oil coolerwas removed or drained of oil, add an extra 0.94L (1 qt.) of oil.

2. Start the engine and check for leaks. Fix leaks asneeded.

3. Shut down the engine and check the oil level. Addoil or drain oil as needed to bring the oil level withinthe FULL and ADD marks on the oil level gauge.Do not overfill past the FULL mark.



ENGINE ELECTRICAL 223

Table of Contents

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225Camshaft Position (CMP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225Exhaust Back Pressure (EBP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225Engine Oil Pressure (EOP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226Engine Coolant Temperature (ECT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226Engine Oil Temperature (EOT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226Injection Control Pressure (ICP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226Injection Pressure Regulator (IPR) Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .227Manifold Absolute Pressure (MAP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .227Intake Air Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .227

Electronic Control Module (ECM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .231Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .231

Main Engine Wiring Harness.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .232Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .232Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .235Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .235Verifying CMP Sensor Clearance (Air Gap). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .236

Glow Plug Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241

Special Torque.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241




224 ENGINE ELECTRICAL




Description

NOTE: Refer to the following for electrical systemtroubleshooting:

EGES190, T 444E Diesel Engine / Vehicle DiagnosticManual

EGED195, Hard Start / No Start Performance EngineDiagnostics Form

EGED200, Electronic Control System DiagnosticsForm

CAMSHAFT POSITION (CMP) SENSOR

Figure 346 CMP Sensor

The CMP sensor is a Hall effect type sensor stacked infront of a magnet with a signal conditioning integrated

circuit. It responds to a rotating actuator positionedon the camshaft gear. The actuator has 24 stampedwindows. This produces a rectangular wave pulse foreach tooth as the actuator rotates past the sensor.The pulses are used to indicate engine speed andcamshaft position for control of fuel quantity, injectiontiming, and overspeed shutdown. The sensor islocated above the vibration damper on the right sideof the engine front cover.

EXHAUST BACK PRESSURE (EBP) SENSOR

Figure 347 EBP Sensor

The EBP sensor is a ceramic diaphragm sensor thatmeasures the exhaust back pressure. It providesfeedback to the ECM for closed loop control of theexhaust back pressure. The result is faster enginewarm-up at cold ambient temperatures. If equipped,the sensor is mounted on a bracket located on thetop right side of the hydraulic reservoir.




ENGINE OIL PRESSURE (EOP) SENSOR

Figure 348 EOP Sensor

The EOP sensor is a ceramic diaphragm sensor thatdetects engine oil pressure and sends the pressuresignal to the ECM. The sensor is located on top of thehigh oil pressure pump reservoir.

ENGINE COOLANT TEMPERATURE (ECT)SENSOR

Figure 349 ECT Sensor

The ECT sensor is a thermistor type sensor thatdetects changes in engine coolant temperature. The

sensor is located above the water pump on the rightside of the engine front cover.

ENGINE OIL TEMPERATURE (EOT) SENSOR

Figure 350 EOT Sensor

The EOT sensor is a thermistor type sensor thatdetects the engine oil temperature and sends theengine temperature signal to the ECM. The ECMthen uses the information for fuel rate and timingadjustments. The sensor is located on the rear leftside of the high pressure oil reservoir.

INJECTION CONTROL PRESSURE (ICP) SENSOR

Figure 351 ICP Sensor

The ICP sensor is a ceramic diaphragm sensor thatmeasures the injection control pressure. It providesgallery pressure feedback to the ECM for a closedloop control of the injector oil pressure. The sensoris located toward the front of the engine on the leftcylinder head, in the high pressure oil rail.




INJECTION PRESSURE REGULATOR (IPR) VALVE

Figure 352 IPR Valve

The IPR valve is a pulse width modulated valve thatregulates the injection control pressure by receiving asignal from the ECM. The valve is located on the leftside of the high pressure oil pump.

MANIFOLD ABSOLUTE PRESSURE (MAP)SENSOR

Figure 353 MAP Sensor

The MAP sensor is a ceramic diaphragm sensorthat indicates manifold boost pressure or vacuumby receiving a signal from the ECM. The sensor islocated on the right side of the intake manifold pipe.

INTAKE AIR TEMPERATURE

Figure 354 IAT Sensor

The Intake Air Temperature (IAT) sensor isa thermistor type sensor that has a variableresistance which changes when exposed to differenttemperatures. The IAT sensor measures intake airtemperature in order to control timing and fuel ratewhile starting the engine in cold weather to limitsmoke emissions.




Figure 355 Engine Top View

1. Electronic Control Module(ECM)

2. Glow Plug Relay3. Manifold Absolute Pressure

(MAP) Sensor4. Injection Control Pressure (ICP)

Sensor

5. Injection Pressure Regulator(IPR) Valve

6. Engine Oil Temperature (EOT)Sensor

7. Engine Oil Pressure (EOP)Sensor

8. Main Engine Wiring Harness




Figure 356 Engine Front View

1. Engine Oil Pressure (EOP)Sensor

2. Camshaft Position (CMP)Sensor

3. Engine Coolant Temperature(ECT) Sensor

4. Exhaust Back Pressure (EBP)Sensor

5. Main Engine Wiring Harness




Electronic Control Module (ECM)Removal

Figure 357 Glow Plug Relay

1. Glow Plug Connector Terminals2. Battery Connection Terminal

1. Disconnect the battery and glow plug connectorsfrom glow plug relay.

Figure 358 ECM Wiring Harnesses and MountingBolts

1. Connector Bolt2. Engine Wiring Harness3. ECM Mounting Bolt (4)

2. Use a square head driver to unscrew theconnector bolt. Disconnect the engine wiringharness from the ECM.

3. To remove the ECM from the support assembly,remove the four mounting bolts and lift the ECMfrom the support bracket.

4. To remove the ECM and support assembly as oneunit, perform the following steps:

Figure 359 ECM Support Assembly LowerMounting Bolts

a. Remove the two lower mounting bolts for theECM support assembly.

Figure 360 ECM Support Assembly UpperMounting Bolts

b. Remove the two upper mounting bolts for theECM support assembly.




Figure 361 Bottom Mounting Bracket

1. Top Bushing2. Bushing Pin3. Bottom Bushing4. Bottom Mounting Bracket

c. If necessary, remove the bushings and pinsfrom the mounting brackets.

Inspection

Figure 362 ECM Mounting Bushings and Pin

1. Bushings2. Pin

1. Inspect ECM mounting bushings for wear anddamage. Replace as necessary.

2. Inspect the wiring harnesses, covers, and covershields for wear and damage. Replace asnecessary.

Installation

1. To install the ECM and support assembly as oneunit, perform the following steps:

Figure 363 ECM Support Assembly Bushingsand Pins

1. Top Bushing2. Bushing Pin3. Bottom Bushing4. Bottom Mounting Bracket

a. If previously removed, install the bushingsand pins in the bolt holes of the supportassembly.

Figure 364 ECM Support Assembly UpperMounting Bolts

b. Install the ECM and support assembly onthe engine. Install and tighten the two uppermounting bolts to the special torque value.




Figure 365 ECM Support Assembly LowerMounting Bolts

c. Install and tighten the two lower mountingbolts to the special torque value.

Figure 366 ECM Wiring Harnesses and MountingBolts

1. Connector Bolt2. Engine Wiring Harness3. ECM Mounting Bolt (4)

2. To install the support assembly and ECMseparately, first perform the procedure in Step1 for the support assembly only. Then install theECM on the support assembly. Install and tightenthe four mounting bolts to the special torquevalue.

3. Connect the engine wiring harness to the ECM.Tighten the connector bolt to the special torquevalue.

Figure 367 Glow Plug Relay

1. Glow Plug Connector Terminals2. Battery Connection Terminal

4. Connect the battery and glow plug connectors tothe glow plug relay terminals.

Main Engine Wiring HarnessRemoval

1. Perform Steps 1 through 7 in the Engine ControlModule (ECM), Removal procedure in thissection.

Figure 368 9–Pin Connector to the Valve CoverGasket

2. Carefully unlatch and disconnect the 9–pinconnectors from the valve cover gasket. There isone connector for each valve cover.




Figure 369 MAP Sensor Connector

1. MAP Sensor2. Sensor Connector

3. Carefully unlatch and disconnect the sensorconnector from the MAP sensor.

Figure 370 EOP Sensor Connector

1. Sensor Connector2. EOP Sensor

4. Carefully unlatch and disconnect the sensorconnector from the EOP sensor.

Figure 371 EBP Sensor Connector

1. Sensor Connector2. EBP Sensor

5. Carefully unlatch and disconnect the sensorconnector from the EBP sensor.

Figure 372 ECT Sensor Connector

1. ECT Sensor2. Sensor Connector

6. Carefully unlatch and disconnect the sensorconnector from the ECT sensor.




Figure 373 CMP Sensor Connector

1. Sensor Connector2. CMP Sensor

7. Carefully unlatch and disconnect the sensorconnector from the CMP sensor.

Figure 374 EOT Sensor Connector

1. EOT Sensor2. Sensor Connector

8. Carefully unlatch and disconnect the sensorconnector from the EOT sensor.

Figure 375 ICP Sensor Connector

1. Sensor Connector2. ICP Sensor

9. Carefully unlatch and disconnect the sensorconnector from the ICP sensor.

Figure 376 IPR Valve Connector

10. Carefully unlatch and disconnect the valveconnector from the IPR valve.

NOTE: For removal of the IPR valve, refer to the“HIGH-PRESSURE OIL PUMP” section.

11. Remove the wiring harness routing clips from thecylinder heads and front cover.




CAUTION: To avoid engine damage, if anyresistance is felt during removal, DO NOT tugon the wiring harness to free it. This coulddamage the wiring harness. Investigate thesource of resistance and free the wiringharness carefully before continuing with theremoval.

12. Carefully lift the engine wiring harness from theengine.

Inspection

1. If any sensors are removed, clean off any threadlocking compound from the sensor threads.

2. Check the connector pins on the sensors. If anypins are bent or corroded, replace the sensor.

3. Carefully inspect the wiring harness for wornconduit, frayed insulation, and heat damage.Repair as necessary.

4. Check each connector for:

• corrosion (green or gray) or white deposits onmetal terminals.

• female connector sleeves that are spreadopen.

• terminals that are incorrectly latched into theconnector body or pushed back relative toother terminals in the same connector.

5. Check the wiring harness connectors, connectorcovers, foam inserts, and cover shields for cracks,cuts, or worn areas. Replace as necessary.

Installation

NOTE: For installation of the IPR valve, refer to theHIGH PRESSURE OIL PUMP section.

1. If removed, install the EOT, ECT, EBP, EOP, andMAP sensors in their proper locations (Removal,page 232).

2. If removed, install the CMP sensor as follows:

a. If necessary, check the clearance of theCMP sensor. Refer to Verify CMP SensorClearance (Air Gap) in this section.

Figure 377 Installing the CMP Sensor

1. CMP Sensor2. Sensor Port3. Bolt Hole

b. Put a new O-ring on the sensor and lubricatethe O-ring with clean engine oil.

c. Insert the sensor into the port. Secure thesensor with the mounting bolt.

3. If removed, install the ICP sensor as follows:

Figure 378 ICP Sensor O-Ring

a. Put a new O-ring on the sensor.

b. Apply Loctite® #277 to the threads of thesensor. Install the sensor in the front leftcylinder head bank and tighten the sensor tothe special torque value.




Figure 379 9–Pin Connector to the Valve CoverGasket

NOTE: To ensure the electrical connection betweenthe wiring harness and the valve cover gasket, installa new retainer clip from service kit P/N 1844193C91on both wiring harness connectors.

4. Connect the two 9–pin connectors to the valvecover gaskets. There is one for each valve cover.

NOTE: Make sure that each connector has its ribbedseal in place before installation into sensor. In somecases, a ribbed seal may pull off its connector duringremoval and remain in the mating socket of a sensoror actuator. A connector that is installed without theappropriate ribbed seal may become contaminatedwith moisture and corrode the terminals, resulting ina poor electrical connection.

5. Install the wiring harness on the engine. Carefullyalign the connectors with the sensors. Push eachconnector into its mating socket until the lockingtabs are fully latched.

6. Install the wiring harness routing clips.

Verifying CMP Sensor Clearance (Air Gap)

NOTE: It is only necessary to verify the sensorclearance if there has been erratic operation.

Engine misfiring may also be caused by a low dieselfuel cetane number. Verify the fuel being used has acetane number of 42 or higher.

Figure 380 Removing CMP Sensor

1. Disconnect CMP sensor wiring harnessconnector.

2. Remove CMP sensor mounting bolt from enginefront cover. Pull CMP sensor out.

3. Clean the sensor mounting surface.

Figure 381 Camshaft Sensor Air Gap Tool InCMP Sensor




4. Insert camshaft sensor air gap tool in calibrationcup of CMP sensor. Hold firm downward pressureon tool and adjust indicator dial to zero. Tightenlock tab on dial ring of air gap tool. The tool is nowcalibrated for the length of the CMP sensor.

5. Install camshaft sensor air gap tool tip against thecamshaft gear trigger wheel tooth. Secure toolto front cover by tightening mounting screw to 1.0N•m (10 in•lbf).

6. Crank the engine with starter or bar engine over byhand. Turn over at least two complete revolutionsprior to recording any readings.

7. Observe needle sweep on dial indicator. Therange sweep is an indication of timing wheelrun–out which should not exceed 0.20 mm (0.008in).

8. Crank engine long enough to get an averagereading of the camshaft sensor air gap tool dialindicator. If an interference condition is observedduring cranking, the CMP sensor may have beendamaged and must be replaced.

9. Perform the math using the CMP SensorClearance Worksheet. Select the appropriatecombination of shims to achieve a measurementas close to 0.026 inch as possible. Refer to theInternational® Service Parts Dealer for the correctshim kit.

10. Install the CMP sensor with the shims required.Insure that the shims are centered on the CMPsensor flange. Use a small amount of grease tohold them in place.

11. Reconnect sensor wiring harness and test engine.

OPTIONAL METHOD

Figure 382 Measuring the Sensor Air Gap

12. Manually rotate the crankshaft clockwise at leasttwo complete revolutions while facing the frontof the engine. Then knock the crankshaft backgently. This ensures that the sensor air gap is atits maximum with the camshaft gear in contactwith its rear thrust face.

NOTE: When taking the following measurement,measure up to the gear tooth on the trigger wheel.DO NOT measure into the window between the teeth.

13. Use a depth micrometer or a precision caliper tocarefully measure the distance (to nearest onethousandth of an inch) from the sensor mountingsurface to the camshaft gear tooth on the triggerwheel. Record the measurement (sensor air gap)on the worksheet.

14. Manually rotate the crankshaft 180 clockwisewhile facing the front of the engine. Repeat Steps12 and 13. Continue this process two more timesso the distance from the cover to the trigger wheelis measured at four different locations.

Variations in these measurements determine therunout of the trigger wheel. The variation shouldnot exceed 0.20 mm (0.008 in).




Figure 383 Measuring the CMP Sensor

1. CMP Sensor2. Depth Micrometer

15. Use a depth micrometer or a precision caliper tocarefully measure the CMP sensor from the tip tothe surface of the mounting flange. Record themeasurement on the worksheet.

16. Perform the math as directed on the worksheet.Then select the appropriate combination of shimsto achieve a measurement as close to 0.026 inchas possible. Refer to your International® ServiceParts Dealer for the correct shim kit.

17. Install the CMP sensor with the necessary shims.Ensure that the shims are centered on the sensorflange. If necessary, use a small amount of greaseto hold them in place.

18. Connect the sensor wiring harness. Test theengine.




Table 24 CMP Sensor Clearance Worksheet

STEP MEASUREMENT

1. Rotate crankshaft clockwise at least two revolutions. Measure distance from CMPsensor mounting surface to gear tooth on trigger wheel.

2. Rotate crankshaft 180 clockwise. Repeat measurement. +



5. Add measurements from Step 1 through Step 4. =

6. Obtain average dimension by dividing Step 5 total by 4. ÷ 4

7. Measure CMP sensor length from tip to surface of mounting flange. -

8 Subtract Step 7 measurement from Step 6 average. =

9. Desired air gap (inches) - 0.026

10. Subtract Step 9 dimension from Step 8 total.

This is the necessary shim thickness.=




Glow Plug RelayRemoval

WARNING: To avoid engine damage,serious personal injury or possibly death,do not use a screwdriver or similar tool topry off the terminal cover. Disconnect thebatteries first due to the presence of batteryvoltage at the relay terminals. Disconnectthe ground terminal first. Always wear eyeprotection when working around batteries.

1. Disconnect the main negative cable from thebatteries.

2. Remove the glow plug relay plastic terminal cover.

Figure 384 Glow Plug Relay DisconnectionPoints

1. Glow Plug Relay Mounting Bolt2. Glow Plug Relay Terminal Stud3. Relay Control Harness Connector4. 12 Volt Power Wire Terminal Stud

3. Disconnect the 12V power wire, glow plug wireand relay control harness connector.

4. Remove the two mounting screws. Lift the glowplug relay from the engine.

Inspection

NOTE: The glow plug relay is not repairable beyondbeing certain that all electrical connections to it areclean and tight.

Inspect the base and relay housing for cracks.Replace if cracks are found.

Installation

1. Install the glow plug relay onto its bracket. Tightenthe two mounting screws.

2. Connect the glow plug wire and 12V power wire tothe top of the glow plug relay. Tighten the terminalnuts.

3. Connect the relay control harness connector tothe glow plug relay.

4. Snap the glow plug relay cover into place.

5. Connect the main negative cable to the batteries.




SPECIFICATIONS

Table 25 Engine Electrical

Glow Plugs:

Location Cylinder Head

Quantity 8

Injection Pressure Regulator (IPR) Valve:

Maximum Flow Rate 17.5 L/m (4.62 gpm)

Maximum Operating Pressure 20.7 MPa (3000 psi)

Camshaft Position Sensor (CMP)

Location Front Cover

Operating Actuator Speed 15 to 2000 RPM

Operating Temperature Range -40 C to +130 C (-40 F to +266 F)

Operating Air Gap Range 0.10 to 0.86 mm (0.004 to 0.034 inch)

Desired Air Gap Measurement 0.66 mm (0.026 inch)

Special Torque

Table 26 Electrical System Special Torques

Glow Plug 19 N·m (14 lbf·ft)

Glow Plug Relay Stud Nuts 8 N·m (70 lbf·in)

Injection Control Pressure (ICP) Sensor 50 ± 5 N·m (37 ± 4 lbf·ft)

ECM Mounting Bolts 24 N·m (18 lbf·ft)

ECM Support Assembly Mounting Bolts 24 N·m (18 lbf·ft)

ECM Mounting Bracket Nuts 24 N·m (18 lbf·ft)

Wiring Harness Connector Mounting Bolt (Engineand Chassis) 3 – 5 N·m (30 – 45 lbf·in)


Table 27 Special Service Tools

ZTSE 4414 Camshaft Sensor Air Gap

OEM 1013 Depth Gage Micrometer



HIGH-PRESSURE OIL PUMP 243

Table of Contents

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .246High-pressure Oil Pump Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .246High-pressure Oil Pump and Drive Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .247Injection Pressure Regulator (IPR) Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .248

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .249Injection Pressure Regulator (IPR) Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .249High-pressure Oil Pump and Drive Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .249Check Drive Gear Backlash.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251High-pressure Oil Pump Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253

Special Torque.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253




244 HIGH-PRESSURE OIL PUMP




Figure 385 Injector Oil System Flow

1. Engine Lube Oil Pump2. Check Valve3. Reservoir (Located on the Top

of Front Cover)4. High-pressure Oil Pump5. High-pressure Lines6. Injection Control Pressure (ICP)

Sensor

7. Cylinder Head High PressureOil Rail

8. Fuel Injector (8)9. Gallery (Crankcase)10. Oil Filter11. Oil Cooler12. Injection Pressure Regulator

(IPR) Valve




RemovalHigh-pressure Oil Pump Reservoir

NOTE: A service kit for servicing the discharge fittingsand rear plug is available for the high-pressure pump.

Figure 386 Removing Oil From High-pressureOil Pump Reservoir

1. Hand Operated Vacuum Pump2. High-pressure Oil Pump Reservoir

1. Remove pipe plug from top left side ofhigh-pressure oil pump reservoir. Use a handoperated vacuum pump to extract oil from thereservoir.

2. Remove power steering pump.

Figure 387 EBP Sensor Location

1. EBP Sensor Bracket Bolts (2)2. EBP Sensor3. EBP Sensor Tube4. EBP Sensor Tube Nuts

3. Remove two bolts that secure the EBP sensorbracket to the right side of the high-pressure oilpump reservoir.

4. Disconnect the EBP sensor tube from the rightexhaust manifold.




Figure 388 Removing Mounting Bolts From theHigh-pressure Oil Pump Reservoir

1. Mounting Bolts2. High-pressure Oil Pump Reservoir

5. Remove the three remaining mounting bolts thatsecure the high-pressure oil pump reservoir to thefront cover. Remove the high-pressure oil pumpreservoir and gasket.

High-pressure Oil Pump and Drive Gear

Figure 389 Removing High-pressure Oil SupplyHoses

1. High-pressure Oil Pump2. Supply Hoses3. Clamp

1. Use the special removal tool to disconnect thehigh-pressure oil supply hoses at the pump andat each cylinder head. Cap the fittings.

2. Disconnect the electrical harness from the IPRvalve solenoid.

Figure 390 Removing Drive Gear Access Cover

1. Drive Gear Access Cover2. Mounting Bolt (2)

3. Remove the two bolts and the drive gear accesscover from the front cover. Clean all RTV sealantfrom the access cover and front cover matingsurface.

Figure 391 Removing Drive Gear Bolt

1. Drive Gear2. Mounting Bolt and Washer

4. Remove bolt and washer that secure the drivegear to the high-pressure oil pump.




Figure 392 Removing High-pressure Oil PumpMounting Bolts

1. Drive Gear2. High-pressure Oil Pump3. Mounting Bolts

5. Remove two capscrews that secure high-pressureoil pump to front cover. Remove pump and gasketfrom front cover.

NOTE: The gasket is reusable.

Figure 393 Removing Drive Gear

1. Front Cover2. Drive Gear

6. Remove the drive gear through the top of the frontcover.

Injection Pressure Regulator (IPR) Valve

NOTE: The IPR valve can be removed before or afterthe high-pressure oil pump is removed.

Figure 394 Removing the IPR Valve Solenoid

1. High-pressure Oil Pump2. IPR Valve3. Solenoid4. Tinnermann Nut

1. Remove the tinnermann nut that secures the IPRvalve solenoid. Remove the solenoid.

Figure 395 Removing the IPR Valve




2. Use a 28 mm (1-1/8 in) deep socket to unscrewthe IPR valve from the high-pressure oil pump.

InstallationInjection Pressure Regulator (IPR) Valve

Figure 396 Installing the IPR Valve

1. Check the O-rings on the IPR valve. Replace theO-rings if damaged.

2. Install the IPR valve into the high-pressure oilpump. Tighten the IPR valve to the special torquevalue.

3. Install the solenoid and tinnermann nut. Tightenthe tinnermann nut to the special torque value.

High-pressure Oil Pump and Drive Gear

Figure 397 Installing High-pressure Oil Pumpand Gasket

1. Gasket2. Front Cover3. High-pressure Oil Pump

1. Insert the high-pressure oil pump drive gear intothe opening on top of the front cover.

2. Position the high-pressure oil pump with thegasket against the front cover.




Figure 398 Installing High-pressure Oil PumpMounting Bolts

1. Front Cover2. Mounting Bolts (2)3. High-pressure Oil Pump

3. Install and tighten the two mounting bolts to thespecial torque value.

Figure 399 Installing the Drive Gear Bolt

1. Drive Gear2. Front Cover3. Drive Gear Mounting Bolt4. Washer

4. Install the drive gear bolt and washer to secure thedrive gear to the high-pressure oil pump. Tightenbolt to the special torque value.

Figure 400 Applying RTV Sealant to the DriveGear Access Cover

1. Drive Gear2. High-pressure Oil Pump3. RTV Bead4. Front Cover

5. Apply RTV sealant to the drive gear access covermounting surface.

Figure 401 Install Drive Gear Access Cover

1. Drive Gear Access Cover2. Mounting Bolt (2)

6. Install the access cover and two mounting bolts.Tighten the bolts to the standard torque value.

7. Connect the engine wiring harness connector tothe IPR valve solenoid.




Figure 402 Installing High-pressure Oil SupplyHoses

1. High-pressure Oil Pump2. High-pressure Oil Supply Hoses3. Hose Clamp

8. Remove the protective caps from the fittings.Install both high-pressure oil supply hoses at thehigh-pressure oil pump and cylinder head. Makesure the hose fittings snap into place.

Check Drive Gear Backlash

Figure 403 Measuring Drive Gear Backlash

1. Dial Indicator2. Drive Gear3. Front Cover

1. Mount the dial indicator.

2. Place the measuring tip of the dial indicator on thegear tooth, tangent to the gear tooth, if possible.

3. Move the gear in one direction and hold it in place.

4. Zero the dial indicator.

5. Move the drive gear by hand in the oppositedirection. Record the backlash.

6. If the backlash exceeds specifications, replace thedrive gear.

High-pressure Oil Pump Reservoir

Figure 404 Installing a Gasket to the ReservoirMating Surface

1. Reservoir Gasket2. High-pressure Oil Pump3. High-pressure Oil Pump Drive Gear4. Front Cover

1. Install a new gasket onto the top of the reservoirmating surface.




Figure 405 Install High-pressure Oil PumpReservoir

1. Exhaust Back Pressure (EBP) Sensor2. High-pressure Oil Pump Reservoir3. Reservoir Mounting Bolts (3)

2. Install the reservoir to the front cover. Secure thereservoir with three mounting bolts.

Figure 406 Installing EBP Sensor

1. EBP Sensor Bracket Bolts (2)2. EBP Sensor3. EBP Sensor Tube4. EBP Sensor Tube Nuts

3. Use two bolts to secure the EBP sensor bracketonto the right side of the high-pressure oil pumpreservoir.

4. Connect the EBP sensor tube to the right exhaustmanifold. Tighten the tube nut.

5. Connect the EBP sensor to the wiring harness.

6. Fill the reservoir with clean engine oil.




SPECIFICATIONS

Table 28 High-pressure Lube Oil System

High-pressure Oil Pump

Gear Backlash 0.140–0.256 mm (0.0055–0.0101 in)

End Play 0.45–1.22 mm (0.018–0.048 in)


Operating Temperature Range -40 to 125 C (-40 to 257 F)

Maximum Flow Rate 17.5 L/min (4.62 gpm)


Special Torque

Table 29 High-pressure Lube Oil System Special Torques

High-pressure Oil Pump Drive Gear Bolt 129 N·m (95 lbf·ft)

IPR Valve Tinnermann Nut 5.5 ± 1.5 N·m (49 ± 13 lbf·in)

IPR Valve 50 ± 5 N·m (37 ± 4 lbf·ft)

High-pressure Hose Fitting (37 Flare) 26 N·m (19 lbf·ft)

45 and 90 Elbow Locknut 28 N·m (21 lbf·ft)


Table 30 High-pressure Lube Oil System Special Service Tools

ZTSE2499 Hand Operated Vacuum Pump

ZTSE4295 High-pressure Oil System Cap Set




FUEL SYSTEM 255

Table of Contents

Fuel Filter Tower, Bracket and Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .258Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .258Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260

Fuel Strainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .261Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .261Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .261

Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .262Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .262Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .262

Fuel Transfer Pump.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .264

Fuel Injectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .264

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .265

Special Torque.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .265




256 FUEL SYSTEM



FUEL SYSTEM 257

Figure 407 Fuel System Components

1. Pump Flange Gasket2. High-pressure Oil Pump

Assembly3. High-pressure Manifold Hose

(Right Side)4. Fuel Injection Pressure

Regulator5. High-pressure Oil Pump Supply

Hose (Left Side)6. Fuel Supply Hose (Left Side)

and Inlet Check Fittings7. Cylinder Head (Left Side)8. Fuel Injector Assembly

9. Fuel Supply Pipe (Right Side)and Inlet Check Fittings

10. Transfer Pump11. Fuel Filter to Transfer Pump12. Fuel Pump Supply Tube13. Fuel Supply Hose from Pump to

Regulator14. Clamp15. Fuel Pump Lines Retaining

Clamp16. Water Drain Tube Clamp

Support17. Clamp

18. Fuel Filter Water Drain Tube19. Fuel Filter Water Drain Hose20. Fuel Hose21. Hose Clamp22. Fuel Filter to Transfer Pump

Tube23. Cylinder Head (Right Side)24. Fuel Filter Bracket25. Fuel Supply Hose (Left Side)26. Fuel Pressure Regulating Valve27. Fuel Filter Element28. Fuel Filter Lid (Part of Assembly)



258 FUEL SYSTEM

Fuel Filter Tower, Bracket andPipingRemoval

WARNING: To avoid serious personalinjury, possible death, or damage to theengine or vehicle, do not smoke or worknear open flames and sparks when drainingfuel.

Figure 408 Fuel Filter Lever Locations

1. Fuel Filter Assembly2. Fuel Filter Shutoff Lever, CLOSED Position3. Fuel Filter Shutoff Lever, DRAIN Position

1. Place a suitable container at the end of the fuelfilter drain line to catch the draining fuel. Move thefuel filter drain lever to the DRAIN position. Whenthe fuel is done draining, return the lever to theCLOSED position.

Figure 409 Removing the Fuel Lines

1. Fuel Supply to Fuel Transfer Pump Line2. Fuel Transfer Pump to Fuel Filter Line3. Retaining Clamp4. Fuel Filter to Fuel Transfer Pump Line5. Fuel Filter Drain Line

2. Remove the bolt for the retaining clamp that holdsthree of the fuel lines together.

3. Loosen the hose clamps and remove all four fuellines.

Figure 410 Removing Hoses from the RegulatingValve

1. Fuel Pressure Regulating Valve2. Fuel Supply Hoses

4. Remove two fuel supply hoses from the fuelpressure regulating valve. Cap the fittings on thecylinder head.



FUEL SYSTEM 259

5. Remove the bolts that secure the fuel pressureregulating valve to the fuel filter. Check fordamage or corrosion.

Figure 411 Removing the Fuel Filter Tower(Model Year 1997–1998)

1. Fuel Filter Tower2. Fuel Filter Support Bracket3. Fuel Filter Tower Mounting Bolts (2)4. Support Bracket Mounting Nuts (4)

Figure 412 Removing the Fuel Filter Tower(Model Years 1999 and Up)


6. Remove the two mounting bolts that secure thefuel filter tower to the fuel filter support bracket.Remove the fuel filter tower from the supportbracket.

7. If necessary, remove the mounting nuts thatsecure the fuel filter support bracket to thecylinder head. Remove the support bracket.



260 FUEL SYSTEM

Installation

Figure 413 Installing the Fuel Filter Tower(Model Year 1997–1998)


Figure 414 Removing the Fuel Filter Tower(Model Years 1999 and Up)


1. If removed, install the support bracket on thecylinder head. Install the four mounting nuts andtighten them to the standard torque value.

2. Install the fuel filter tower on the support bracket.Install the two mounting bolts and tighten them tothe standard torque value.

Figure 415 Installing Hoses to Regulating Valve

1. Fuel Pressure Regulating Valve2. Fuel Hoses

3. Install a new O-ring onto the fuel pressureregulating valve.



FUEL SYSTEM 261

4. Secure the regulating valve to the fuel filter withtwo mounting bolts. Tighten the bolts to thestandard torque value.

5. Attach the fuel supply hoses to the fuel pressureregulating valve. Tighten the hose fittings.

Figure 416 Attaching the Fuel Lines

1. Fuel Supply to Fuel Transfer Pump Line2. Fuel Transfer Pump to Fuel Filter Line3. Retaining Clamp4. Fuel Filter to Fuel Transfer Pump Line5. Fuel Filter Drain Line

6. Attach the three fuel lines between the fueltransfer pump and the fuel filter.

7. Install the retaining clip and bolt to hold the threefuel lines together.

8. Attach the fuel filter drain line. Secure it to the fuelfilter with hose clamps.

Fuel StrainerRemoval

Figure 417 Removing the Fuel StrainerAssembly

1. Remove the fuel strainer assembly from the fuelfilter housing.

2. Use a 29 mm or 1-1/8 inch socket to remove theplastic fuel strainer cover from the filter strainerassembly. Clean or replace the fuel strainer.

Installation

Figure 418 Installing the Fuel Strainer

1. Fuel Strainer2. O-Ring



262 FUEL SYSTEM

NOTE: Install the fuel strainer with the open endtoward the top.

1. Install a new O-ring. Lubricate the threads ofthe fuel strainer cover and the O-ring with cleanengine oil.

2. Install the new fuel strainer into the cover. Handtighten the strainer into the fuel filter body.

Fuel FilterRemoval

Figure 419 Removing the Fuel Filter Cap

1. Use a large screwdriver to remove the fuel filtercap. The filter element will come out with the cap.

Figure 420 Removing the Fuel Filter ElementAssembly

1. Fuel Filter Cap2. Fuel Filter Element3. Fuel Filter Locking Tab4. Bevel-Cut Gasket

2. Remove and discard the bevel-cut gasket.Carefully clean all mating surfaces.

3. Press in on the fuel filter element locking tabs andseparate the filter element from the cap.

Installation

CAUTION: The engine will not run withoutthe filter element in place. Failure to securethe fuel cap to the fuel filter may result inengine damage because the filter element isrequired to open the valve in the center standpipe. When the valve is open, fuel is allowedto flow into the filter. This feature protectsthe injectors from contaminants if the filterelement is left out.

NOTE: If the fuel system has been drained, primethe fuel filter by filling the filter housing up to the capthreads with clean diesel fuel.



FUEL SYSTEM 263

Figure 421 Installing a New Fuel Filter Element

1. Fuel Filter Cap2. Fuel Filter Element3. Bevel-Cut Gasket4. Fuel Filter Housing

1. Apply a coating of diesel fuel to the new bevel-cutgasket and install it on the fuel filter housing gland.

2. Install a new fuel filter element on the cap. Placethe new fuel filter element and cap into the fuelfilter housing. Tighten the cap onto the fuel filterhousing until the cap contracts the aluminumhousing.

Fuel Transfer PumpRemoval

Figure 422 Removing the Fuel Transfer Pump

1. Lines from Pump to Filter2. Fuel Transfer Pump3. Fuel Supply Tube (to Regulating Valve)4. Fuel Supply Tube (Right Side)

1. Disconnect the lines between the fuel transferpump and the fuel filter. Plug the lines.

2. Disconnect both fuel supply tubes from the fueltransfer pump. Plug the tubes.

3. Remove the two mounting bolts that secure thefuel transfer pump to the base of the crankcase.

4. Rotate the engine by hand until the pump ispushed up approximately 1/2 inch. This placesthe cam lobe at the top. In this position, if thetappet falls out of the pump during removal, it willnot enter the crankcase.

5. Remove the fuel transfer pump.

6. If required, retrieve the tappet from the fueltransfer pump bore located in the crankcase.Insert the tappet into the base of the fuel transferpump.

Inspection

Inspect the fuel transfer pump tappet for wear.



264 FUEL SYSTEM

Installation

Figure 423 Installing a New O-Ring Onto theFuel Transfer Pump

1. Fuel Transfer Pump2. O-Ring3. Tappet

1. Install a new O-ring onto the fuel transfer pump.

2. Rotate the engine by hand until the fuel transferpump is pushed nearly flush with the crankcase.Install the mounting bolts to the standard torquevalue.

3. Remove the plugs from the fuel supply tubes.Place new O-rings onto the tube fittings. Connectthe fuel supply tubes to the pump.

4. Connect the lines between the fuel transfer pumpand the fuel filter.

Fuel Injectors

NOTE: Refer to the CYLINDER HEAD AND VALVESsection, for fuel injector removal and installationinstructions.



FUEL SYSTEM 265

SPECIFICATIONS

Table 31 Fuel System Specifications

Fuel Filter

Type Spin-On with Fuel Strainer

Fuel Pressure Regulating Valve

Valve open 496 kPa (72 psi)

Heater element activates 7 ± 14 C (45 ± 6.5 F)

Heater element deactivates 24 ± 13 C (75 ± 8.5 F)

Special Torque

Table 32 Fuel System Special Torques

Fuel Return Hose Fitting 16 N·m (12 lbf·ft)

Fuel Supply Tube Bolt (Lift Pump Banjo Fitting) 54 N·m (40 lbf·ft)


Table 33 Fuel System Special Service Tools

ZTSE4294 Fuel System Cap Set



266 FUEL SYSTEM



APPENDIX A – SPECIFICATIONS 267

Table of Contents

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .269



268 APPENDIX A – SPECIFICATIONS




NOTE: MOUNTING ENGINE ON STAND, andOIL COOLER AND FILTER sections, have nospecifications that are necessary for service work.

SPECIFICATIONS

Table 34 Turbocharger

EBP Control Rod Spring Preload 13.5 ± 3 N·m (10 ± 2 lbf)

Turbine Shaft Axial End Play 0.02 - 0.10 mm (0.001 - 0.004 in.)

Turbine Shaft Radial Movement (Play) 0.08 - 0.15 mm (0.003 - 0.006 in)

Wastegate Actuator Movement (Standard Torque Model) 1.016 mm @ 101.35 ± 3.45 kPa (0.4 in @ 14.7 ± 0.5 psi)

Wastegate Actuator Movement (High Torque Model) 0.369 mm @ 131 kPa (0.015 in @ 19 psi)

Table 35 Manifolds

Between ports: 0.13 mm (0.005 in)Maximum Allowable Warpage

Total: 0.25 mm (0.010 in)

Maximum Allowable Removal of Material 0.25 mm (0.010 in)




Table 36 Cylinder Head

Exhaust Valves




Valve Face Angle 37.5


Intake Valves




Valve Face Angle 30


Cylinder Heads

Inside Diameter Of Valve Guide 7.978-8.004 mm (0.3141-0.3151 in)

Valve Guide Taper (Max.) 0.10 mm (0.004 in)

Valve Seat Width (intake and exhaust) 1.65-2.41 mm (0.065-0.095 in)

Valve Seat Angle (intake) 30

Valve Seat Angle (exhaust) 37.5

Valve Seat Run Out (T.I.R. Max.) 0.05 mm (0.002 in)

Gasket Surface Flatness 0.025 mm in 0.5 mm (0.001 in. in 2 inches) 0.10 mm (0.004 in) overall

Gasket Surface Finish (Micro Inches) 63-125

Deck To Deck Dimension (Head ThicknessOverall) 129.41-129.67 mm (5.095-5.105 in)

Valve Head Recession Relative To Deck (Head Gasket) Surface On Cylinder Head

Intake 1.17-1.47 mm (0.046-0.058 in)

Exhaust 1.32-1.63 mm (0.052-0.064 in)

Valve Spring

Free Length 52.70 ± 3.8 mm (2.075 ± 0.150 in)

Test Length 34.34 mm (1.352 in)

Load at Test Length 102-113 kg (225-249 lbf)

Push Rod Runout/Straightness (Max. T.I.R.) 0.518 mm (0.02 in)




Table 37 Vibration Damper, Lubricating Oil Pump, Oil Pan, Oil Pick-Up Tube and Front Cover

Lubricating Oil Pump

Type Gerotor

End Clearance - inner and outer rotor to housing 0.02-0.08 mm (0.001-0.003 in)

Radial clearance between outer rotor housing 0.71-0.81 mm (0.028-0.032 in)

Engine Lube Oil Pressure at Operating Temperature

At low idle speed (700 rpm) minimum 69 kPa (10 psi)

At high idle speed 241-483 kPa (35-70 psi)

Engine Oil Capacity

Without filter 17 liters (18 quarts)

With filter 18.5 liters (19.5 quarts)

Vibration Damper

Vibration damper mounting area runout (maximum) 0.13 mm (0.005 in)




Table 38 Valve Train

Camshaft

Bearing Journal Diameter (All Journals) 53.31-53.34 mm (2.099-2.100 in)

Bearing (Bushing) Inside Diameter 53.39-53.48 mm (2.102-2.105 in)

Journal/Bushing Running Clearance 0.051-0.165 mm (0.002-0.006 in)

Camshaft End Play 0.051-0.203 mm (0.002-0.008 in)

Timing Gear Backlash 0.140-0.2794 mm (0.0055-0.0110 in)

Maximum Permissible Cam Lobe Wear 0.51 mm (0.020 in)

Journal Surface Finish (microinches) 16 µin

Camshaft Thrust Plate Thickness 3.910-3.960 mm (0.154-0.156 in)

Camshaft Lobe Lift

Intake 6.44 mm (0.2535 in) max.

Exhaust 6.43 mm (0.2531 in) max.

Valve Timing No. 1 Cylinder (Top of Ramp)

Intake Open 17.2 BTDC

Closed 34.8 ABDC

Exhaust Open 51.2 BBDC

Closed 20.8 ATDC

Hydraulic Valve Lifters

Diameter 23.391-23.411 mm (0.9209-0.9217 in)

Bore Diameter In Crankcase 23.439-23.477 mm (0.9228-0.9243 in)

Clearance In Bore 0.027-0.086 mm (0.0011-0.0034 in)

Bleed Down Rate – Time required for plunger to move3.175 mm (0.125 in) under a 50 lb load using testfluid at room temperature

18-90 seconds

Table 39 Crankcase, Camshaft Bushing, Crankshaft and Main Bearing, Connecting Rod and Piston

CRANKSHAFT

Main Bearing Journal Diameter





Main Bearing Journal Maximum Out-of-Round 0.00559 mm (0.00022 in)

Main Bearing Thrust Face Runout (T.I.R. maximum) 0.0254 mm (0.001 in)

Main Bearing Journal Taper (max. per inch) 0.381 mm (0.0015 in)





Main Journal Fillet Radius, Journal No. 1, 2, 3 and 4 3.302 mm (0.130 in)

Main Journal Fillet Radius, Journal No. 5 3.99 - 4.14 mm (0.157 - 0.163 in)

Rod Journal Fillet Radius 3.68 mm (0.145 in)

Oil Seal Journal Runout (maximum) 0.05 mm (0.002 in)

Flywheel Housing Bore Concentricity (maximum) 0.20 mm (.008 in)

Flywheel Housing Face Runout (maximum) 0.51 mm (0.020 in)

Flywheel Surface Runout (maximum) 0.05 mm (0.002 in)

Flywheel Thickness (minimum) (See flywheel reconditioningFigure 251.) 44.907 mm (1.768 in)

Thrust Taken By No. 5 Main

Thrust Bearing Journal Length 31.509 - 31.585 mm (1.2405 - 1.2435 in)

Main Bearing Inner Diameter (Installed) 79.385 - 79.436 mm (3.1254 - 3.1274 in)

Main Bearing to Crankshaft Running Clearance 0.046 - 0.117 mm (0.0018 - 0.0046 in)

Connecting Rod Journal Diameter





Connecting Rod Journal, Maximum Out-of-Round 0.0056 mm (0.00022 in)

Connecting Rod Journal Taper (max. per inch) 0.0066 mm (0.00026 in)

Connecting Rod Bearing to Crankshaft Running Clearance 0.038 - 0.114 mm (0.0015 - 0.0045 in)

Crankshaft Flange Outer Diameter 111.05 - 111.15 mm (4.372 - 4.376 in)

Crankshaft End Play 0.063 - 0.216 mm (0.0025 - 0.0085 in)

Crankshaft End Play Maximum Wear Limit 0.51 mm (0.020 in)

Rod to Crankshaft Side Clearance 0.30 - 0.61 mm (0.012 - 0.024 in)

Crankshaft Straightness (T.I.R. Maximum) 0.10 mm (0.004 in)

Crankshaft Gear Backlash (0.1397 - 0.02794 mm (0.0055 - 0.0110 in)

CRANKCASE

Crankcase Deck Flatness 0.025 mm per 50.8 mm, 0.10 mm Total (0.001in. per 2 inches, 0.004 in Total)

Crankcase Main Bearing Bore Diameter 84.206 - 84.231 mm (3.3152 - 3.3162 in)

Crankcase Cam Bearing Bore Diameter 56.655 - 56.693 mm (2.2305 - 2.2320 in)

Valve Lifter Bore Diameter 23.439 - 23.477 mm (0.9228 - 0.9243 in)

Valve Lifter Outer Diameter 23.391 - 23.411 mm (0.9209 - 0.9217 in)





Oil Jet Tube Bore Diameter (Spray Hole Diameter) 0.91 - 1.32 mm (0.036 - 0.052 in)

Cylinder Bore Taper (Top to Bottom) 0.076 mm (0.003 in)

Cylinder Bore Diameter 104.384 - 104.402 mm (4.1096 - 4.1103 in)

Cylinder Bore Maximum Out-of-Round 0.05 m (0.002 in)

Centerline of Main Bearing Bore to Head Deck 287.73 - 287.83 mm (11.328 - 11.332 in)

Oil Seals (Front and Rear Seal Face Runout With Plates InstalledOn Engine) 0.38 mm (0.015 in) T.I.R. Max.

CONNECTING RODS

Connecting Rod Length Center to Center 181.10 mm (7.130 in)

Bushing Bore Diameter (Pin End) 33.235 - 33.243 mm (1.3085 - 1.3088 in)

Piston Pin Bushing Inner Diameter 32.83 - 32.84 mm (1.2924 - 1.2929 in)

Bearing Bore Diameter (Crankshaft End) 68.339 - 68.364 mm (2.6905 - 2.6915 in)

Bearing Bore Maximum Out-of-Round 0.013 mm (0.0005 in)

Bearing Bore Maximum Taper / Inch 0.013 mm (0.0005 in)

Connecting Rod Bearing Inner Diameter 63.513 - 63.564 mm (2.5005 - 2.5025 in)

Connecting Rod Bearing Running Clearance 0.038 - 0.114 mm (0.0015 - 0.0045 in)

Connecting Rod Side Clearance 0.30 - 0.61 mm (0.012 - 0.024 in)

Twist 0.05 mm/in (0.002 in/in)

Bend 0.025 mm/in (0.001 in/in)

Weight - Complete Rod Without Bearing (Old Style)

Weight - Complete Rod Without Bearing (New Style)

1.058 - 1.446 kg (1058 - 1446 g)

1.202 - 1.216 kg (1201.5 - 1215.5 g)

Pin to Bushing Clearance 0.010 - 0.023 mm (0.0004 - 0.0009 in)

PISTONS

Skirt Diameter — Measure 43 mm (1.684 in) below oil groove, at90 angle to the piston pin. Measure only at room temperature of19-21 C (66-70 F).

104.34 - 104.44 mm (4.108 - 4.112 in)

Service Piston





Piston Protrusion Above Crankcase Deck 0.58 – 0.84 mm (0.023 – 0.033 in)

Clearance In Cylinder Bore No. 1 – 8 0.112 - 0.1491 mm (0.0044 - 0.00587 in)

Top compression ring groove width - Measure over 2.92 mm (0.1150 in) gauge pins:





Upper Limit 104.85 mm (4.128 in)

Replacement Limit 104.06 mm (4.097 in)

Piston Pins

Length 75.9 - 76.2 mm (2.99 - 3.00 in)

Diameter 33.220 - 33.226 mm (1.3079 - 1.3081 in)

Pin fit @ room temperature, 19-21 C (66-70 F):

Clearance In Rod 0.010 - 0.023 mm (0.0004 - 0.0009 in)

Clearance In Piston 0.007 - 0.018 mm (0.0003 - 0.0007 in)

End Clearance 0.10 - 0.76 mm (0.004 - 0.030 in)

Piston Rings

Ring Diameter (Standard)

Compression Top (Full Keystone (Barrel Face) Plasma Coated) 104.4 mm (4.11 in)

Compression 2nd (Rectangular Negative Twist - Tapered Face) 104.4 mm (4.11 in)

Oil Control (One Piece Conformable with Chrome ExpanderSpring) 104.4 mm (4.11 in)

Fit in Groove (Side Clearance)

2nd 0.05 - 0.10 mm (0.002 - 0.004 in)

Oil Control 0.023 - 0.074 mm (0.0009 - 0.0029 in)

Ring Gap in Bore

Top 0.35 - 0.61 mm (0.014 - 0.024 in)

2nd 1.57 - 1.82 mm (0.062 - 0.072 in)

Oil Control 0.30 - 0.61 mm (0.012 - 0.024 in)

Table 40 Thermostat and Coolant Filter

Thermostat

Type Poppet Valve, Pellet Operated

Operating Start-to-Open Temperature 89 ± 2 C (192 ± 4 F)

Maximum Full-Open Temperature 104 C (219 F)

Sleeve Travel at Full-Open Temperature 8 mm (0.315 in)

Coolant Filter

Type Spin-On

Length of Filter 106 mm (4.18 in)




Table 41 Engine Electrical

Glow Plugs

Location Cylinder Head

Quantity 8


Maximum Flow Rate 17.5 L/m (4.62 gpm)


Camshaft Position Sensor (CMP)

Location Front Cover

Operating Actuator Speed 15 to 2000 RPM

Operating Temperature Range -40 C to +130 C (-40 F to +266 F)

Table 42 High-pressure Lube Oil System

High-pressure Oil Pump

Gear Backlash 0.140–0.256 mm (0.0055–0.0101 in)

End Play 0.45–1.22 mm (0.018–0.048 in)


Operating Temperature Range -40 to 125 C (-40 to 257 F)

Maximum Flow Rate 17.5 L/min (4.62 gpm)


Table 43 Fuel System

Fuel FilterType Spin-on with fuel strainer

Fuel Pressure Regulating ValveValve open 496 kPa (72 psi)

Heater element activates 7 ±14 C (45 ± 6.5 F)

Heater element deactivates 24 ± 13 C (75 ± 8.5 F)



APPENDIX B — TORQUES 277

Table of Contents

General Torque Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .279

Special Torque.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .281



278 APPENDIX B — TORQUES




General Torque Guidelines

CAUTION: To avoid engine damage, do notsubstitute fasteners. Original equipmentstandard hardware is defined as Class 10.9metric or Type 8 standard coarse threadbolts and nuts and hardened flat washers(Rockwell “C" 38-45), all phosphate coated.

The standard torque charts provide the tighteningtorque for general purpose applications using originalequipment standard hardware as listed in the PartsCatalog for the application involved.

Table 44 Standard Torques – Pipe Thread

Thread Size Torque1

1/8 in NPT 11 N·m (90 lbf·in)



1/2 in NPT 34 N·m (25 lbf·ft)

3/4 in NPT 41 N·m (30 lbf·ft)

1 Tolerances are ±10% of nominal value.

Table 45 Standard Torques — Class 10.9 MetricBolts and Studs

ThreadDiameter

ThreadPitch(mm/thread)

Torque1

6 mm 1 13 N·m (115 lbf·in)

8 mm 1.25 31 N·m (23 lbf·ft)

10 mm 1.5 62 N·m (45 lbf·ft)

12 mm 1.75 107 N·m (79 lbf·ft)

14 mm 2 172 N·m (127 lbf·ft)

15 mm 2 216 N·m (159 lbf·ft)

16 mm 2 266 N·m (196 lbf·ft)

18 mm 2.5 368 N·m (272 lbf·ft)

20 mm 2.5 520 N·m (384 lbf·ft)


Table 46 Standard Torques — Class 12.9 MetricBolts and Studs

ThreadDiameter

ThreadPitch(mm/thread)

Torque1

6 mm 1 15 N·m (132 lbf·in)

8 mm 1.25 36 N·m (27 lbf·ft)

10 mm 1.5 72 N·m (53 lbf·ft)

12 mm 1.75 126 N·m (93 lbf·ft)

14 mm 2 201 N·m (148 lbf·ft)

15 mm 2 252 N·m (186 lbf·ft)

16 mm 2 311 N·m (230 lbf·ft)

18 mm 2.5 430 N·m (317 lbf·ft)

20 mm 2.5 608 N·m (448 lbf·ft)





Figure 424 Classification and Identification – Metric Fasteners

Figure 425 Classification and Identification – Special Use Fasteners

Many conditions affect torque and the results oftorque applications. The major purpose in tighteninga fastener to a specified torque is to obtain tension inthe fastener (i.e., bolt, nut, etc.), which in turn developsa clamping load which exceeds any possible loadingimposed on parts due to engine rpm or vibration.

New phosphate coated fasteners do not require oillubrication during assembly and torque application.Reused fasteners (even if originally phosphatecoated) do require oil lubrication to the threads andunder head area for proper torque application.




Threads that are dry, excessively rough, battered orfilled with dirt require considerable effort just to rotate.Then when the clamping load is developed or the bolttension is applied, the torque reading mounts rapidly(due to thread friction) to the specified torque value.However, the desired bolt tension and maximumclamping effect is not achieved. This condition canlead to failure of the fastener to maintain componentintegrity. The proper bolt tension and clamping effectcan never be attained if the fastener is dry. Thefastener threads must have a film of clean lubricant(engine oil) to be considered lubricated.

Special Torque

NOTE: The THERMOSTAT AND COOLANT FILTERand OIL COOLER AND FILTER sections, have nospecial torques that are necessary for service work.

Table 47 Engine Mounting Special Torques


Table 48 Turbocharger Special Torques

Air Inlet Hose Clamps 4 N·m (36 lbf·in)

Compressor Outlet Clamp 2 N·m (19 lbf·in)

Exhaust Back Pressure Valve to Turbine Housing MountingBolts 21-24 N·m (15-18 lbf·ft)

Exhaust Inlet Clamp 5.6 N·m (50 lbf·in)

Exhaust Tube to Exhaust Inlet Adapter Flange Bolts 28 N·m (21 lbf·ft)

Exhaust Tube to Exhaust Manifold Flange Bolts 26 N·m (19 lbf·ft)

Turbocharger Pedestal to Crankcase Mounting Bolts 24 N·m (18 lbf·ft)

Turbocharger to Pedestal Mounting Bolts (Standard TorqueModel) 47–51 N·m (34–37 lbf·ft)

Turbocharger to Pedestal Mounting Bolts (High Torque Model) 49 N·m (36 lbf·ft)

Table 49 Manifolds Special Torques

Intake Manifold Cover Bolts 24 N·m (18 lbf·ft)

Exhaust Manifold Mounting Bolts 61 N·m (45 lbf·ft)

Exhaust Manifold Flanges 28 N·m (21 lbf·ft)




Figure 426 Exhaust Manifold Mounting Bolt Torque Sequence

1. Start all exhaust manifold mounting boltsinto the holes by hand. Tighten all exhaustmanifold mounting bolts to 61 N·m (45 lbf·ft)in the numerical sequence shown.

2. Tighten all exhaust manifold mounting bolts to61 N·m (45 lbf·ft) again in an inline sequencefrom the rear to the front. Start at the arrow.




Figure 427 Intake Manifold Mounting Bolt Torque Sequence

Start all intake manifold mounting bolts into the holesby hand. Tighten the mounting bolts to 24 N·m (18lbf·ft) in the numerical sequence shown.




Table 50 Cylinder Head Special Torques

Crankcase Breather Screws 2 N·m (18 lbf·in)

Initial: 54 N·m (40 lbf·ft)

Second: 95 N·m (70 lbf·ft)Cylinder Head Mounting Bolts (special torquesequences)

Final: 129 N·m (95 lbf·ft)

Fuel Injector Hold Down Clamp Mounting Bolt 14 N·m (120 lbf·in)

Fuel Injector Shoulder Bolt 14 N·m (120 lbf·in)

Fuel Rail End Plugs 16.3 N·m (12 lbf·ft)

Glow Plugs 19 N·m (14 lbf·ft)

ICP Sensor 29 ± 2 N·m (21.5 ± 1.5 lbf·ft)

Oil Deflector Mounting Bolt 12 N·m (106 lbf·in)

Oil Rail Drain Plugs 6.8 ± 1 N·m (60 ± 10 lbf·in)

Oil Rail End Plugs 81 N·m (60 lbf·ft)

Oil Rail Plugs 29 ± 2 N·m (21.5 ± 1.5 lbf·ft)

Valve Cover Bolts (special torque sequence) 11 N·m (8 lbf·ft)

Valve Lever Mounting Bolt 27 N·m (20 lbf·ft)

Figure 428 Valve Cover Bolt Special Torque Sequence




Figure 429 Cylinder Head Mounting Bolt Special Torque Sequence



3. Tighten to 129 N·m (95 lbf·ft) in line sequence.

4. Tighten to 129 N·m (95 lbf·ft) again in linesequence.

Table 51 Vibration Damper, Lubricating Oil Pump, Oil Pan, Oil Pick-Up Tube and Front Cover SpecialTorques


Oil Pan Mounting Bolts 34 N·m (25 lbf·ft)

Oil Pick-Up Tube Flange Mounting Bolts 24 N·m (18 lbf·ft)


Vibration Damper Mounting Bolt 287 N·m (212 lbf·ft)

Water Pump Pulley Mounting Screw 41 ± 7 N·m (30 ± 5 lbf·ft)

Table 52 Valve Train Special Torques

Cam Follower Guide Mounting Bolt 20 N·m (15 lbf·ft)




Table 53 Crankcase, Crankshaft, Connecting Rods and Piston Special Torques

First Step: 71 N·m (52 lbf·ft)Connecting (4 lbf-ft) Rod Mounting Nuts (Old Style)


First Step: 71 N·m (52 lbf·ft)Connecting Rod Bearing Bolts (New Style)


Flywheel gear access cover bolts 5 N·m (4 lbf-ft)

Flywheel Mounting Bolts 121 N·m (89 lbf·ft)

First Step: 102 N·m (75 lbf·ft)Main Bearing Cap Mounting Bolts


Oil Pick up Tube Flange Bolts 24 N·m (18 lbf·ft)

Piston Cooling Jet Mounting Bolts 11 N·m (100 lbf·in)

Table 54 Electrical System Special Torques

Glow Plug 19 N·m (14 lbf·ft)

Glow Plug Relay Stud Nuts 8 N·m (70 lbf·in)

Injection Control Pressure (ICP) Sensor 50 ± 5 N·m (37 ± 4 lbf·ft)

ECM Mounting Bolts 24 N·m (18 lbf·ft)

ECM Support Assembly Mounting Bolts 24 N·m (18 lbf·ft)

ECM Mounting Bracket Nuts 24 N·m (18 lbf·ft)

Wiring Harness Connector Mounting Bolt (Engineand Chassis) 3 – 5 N·m (30 – 45 lbf·in)

Table 55 High-pressure Lube Oil System Special Torques

High-pressure Oil Pump Drive Gear Bolt 129 N·m (95 lbf·ft)

IPR Valve Tinnermann Nut 5.5 ± 1.5 N·m (49 ± 13 lbf·in)

IPR Valve 50 ± 5 N·m (37 ± 4 lbf·ft)

High-pressure Hose Fitting (37 Flare) 26 N·m (19 lbf·ft)

45 and 90 Elbow Locknut 28 N·m (21 lbf·ft)

Table 56 Fuel System Special Torques

Fuel Return Hose Fitting 16 N·m (12 lbf·ft)

Fuel Supply Tube Bolt (Lift Pump Banjo Fitting) 54 N·m (40 lbf·ft)



APPENDIX C — SPECIAL SERVICE TOOLS 287

Table of Contents




288 APPENDIX C — SPECIAL SERVICE TOOLS




NOTE: The MANIFOLDS, OIL COOLER ANDFILTER, and ELECTRICAL SYSTEM sections haveno special service tools that are necessary for servicework.


Table 57 Engine Mounting Special Service Tools

ZTSE4151A Rear Mounted Engine Bracket (Keine Stand) (Not shown)

ZTSE4348 Side Mounted Engine Bracket (OTC Stand)

OEM4137 Engine Turn-Over Stand

Table 58 Turbocharger Special Service Tools

OEM1028 Dial Indicator with Magnetic Base

ZTSE4293 Turbocharger Intake Shield


ZTSE4230 Spring Tension Scale 0–34 N·m (0-25 lbf)




Table 59 Cylinder Head Special Service Tools

OEM1004 Outside Micrometer (5–6 inch)

OEM1014 Dial Caliper

OEM1023 Small Hole Gauge Set

OEM1272 Defect Detection Kit (Dye Penetrant)


OEM6343 Cleaning Brush

OEM6459 Surface Height Gauge Tool

ZTSE1631A Eccentric Valve Seat Grinder


ZTSE1879 Slide Hammer Puller Kit

ZTSE2241 Valve and Clutch Spring Tester


ZTSE4297 Cylinder Head Lifting Bracket


ZTSE4299 Fuel Injector Holder Rack


ZTSE4301 Fuel Injector Tip Cleaning Brush

ZTSE4302A Fuel Injector Sleeve Removal Tool

ZTSE4303 Fuel Injector Sleeve (Adapter) Replacer

ZTSE4304 Fuel Injector Sleeve Cleaning Brush Set

ZTSE43042 Injector Sleeve Bottom Brush

ZTSE4308 Cylinder Head Pressure Test Plate

ZTSE4320 Oil and Fuel Gallery Brush Cleaning Set (Consists of 4 brushes)

ZTSE4353 Fuel Injector Installation Tool


ZTSE43862 Hand Tap (Bottoming M12 X 1.75)

ZTSE43021A Injector Sleeve Tap




Table 60 Vibration Damper, Lubricating Oil Pump, Oil Pan, Oil Pick-Up Tube and Front Cover SpecialService Tools



ZTSE229569 Vibration Damper Removal Tool

ZTSE4300 Fuel Injector/Front Oil Seal Removal Tool

ZTSE4310 Front Oil Seal/Vibration Damper Installation Tool

ZTSE4314 Vibration Damper Wear Ring Removal Tool

ZTSE4315 Vibration Damper Wear Ring Installation Tool

ZTSE4385 Oil Pan Removal Tool

Table 61 Valve Train Special Service Tools

OEM1000 Micrometer


ZTSE1893 Hydraulic Valve Lifter Tester




Table 62 Crankcase, Crankshaft, Connecting Rods and Piston Special Service Tools

D81L6002B Plastigage®

OEM1000 Micrometer

OEM1022 Telescoping Gauge Set

OEM1023 Telescoping Gauge


OEM1032 Dial Bore Gauge

OEM1293 Straight Edge

OEM6270 120 Grit Glaze Breaker Brush

OEM6453 Piston Retaining Ring Pliers

ZTSE1897E Camshaft Bushing Removal/Installation Set

ZTSE1942A Crankshaft Rear Oil Seal Installation Tool

ZTSE3020 Piston Groove Wear Measuring Tool Set

ZTSE4155A Expansion Plug Replacement Tool

ZTSE4220 Piston Ring Expander

ZTSE4311 Connecting Rod Installation/Remover Guide Pins

ZTSE4317 Crankshaft Wear Ring Removal Tool

ZTSE4318 Rear Oil Seal Installation Tool

ZTSE4375 Flywheel Installation/Removal Guide Studs

ZTSE4385 Oil Pan/Rear Oil Seal Cutting Tool

ZTSE4389 Oil Galley Cleaning Brush

Table 63 Thermostat and Coolant Filter Special Service Tools

OEM6413 Strap Wrench

Table 64 High-pressure Lube Oil System Special Service Tools

ZTSE2499 Hand Operated Vacuum Pump

ZTSE4295 High-pressure Oil System Cap Set


Table 65 Fuel System Special Service Tools

ZTSE4294 Fuel System Cap Set



Printed in the United States of America

1997 2003.dt444.engine.service.manual

Documents

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safety information section

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